JP2020086273A - Antiglare film, manufacturing method of antiglare film, optical member and picture display unit - Google Patents

Abstract

To provide an antiglare film preventing reflection.SOLUTION: An antiglare film 10 includes an antiglare layer (B)12 laminated on a light permeable substrate (A)11. In the antiglare film 10, irregularities are formed on an outermost surface at the antiglare layer (B)12 side. In the antiglare film 10, the irregularities satisfy equations (1) and (2): Ry≥1 (1); and θa≥0.7 (2). In the equation (1), Ry is a maximum height [μm] of projections of the irregularities, and in the equation (2), θa is an average tilt angle [°] of the irregularities.SELECTED DRAWING: Figure 1

Description

The present invention relates to an antiglare film, a method for manufacturing an antiglare film, an optical member, and an image display device.

Various image display devices such as a cathode ray tube display device (CRT), a liquid crystal display device (LCD), a plasma display panel (PDP) and an electroluminescence display (ELD) include fluorescent lamps and sunlight on the surface of the image display device. Is subjected to anti-glare treatment to prevent a reduction in contrast due to reflection of external light or reflection of an image. Especially, as the screen of an image display device becomes larger, an anti-glare film is formed. The number of attached image display devices is increasing.

Although there are many documents describing the antiglare film, there are Patent Documents 1 and 2, for example.

JP, 2009-109683, A JP, 2003-202416, A

From the viewpoint of visibility, the antiglare film needs to be suppressed from being reflected by external light.

For example, in recent years, the demand for public information displays (PID) has increased. PIDs are often used outdoors. When a display (image display device) is used outdoors, reflection due to external light is more likely to occur than when used indoors. When reflection occurs, the image may be difficult to see.

Therefore, an object of the present invention is to provide an antiglare film in which glare is suppressed, a method for manufacturing an antiglare film, an optical member, and an image display device.

In order to achieve the above object, the antiglare film of the present invention,
An antiglare film having an antiglare layer (B) laminated on a light transmissive substrate (A),
Unevenness is formed on the outermost surface of the antiglare film on the antiglare layer (B) side,
It is characterized in that the unevenness satisfies the following mathematical formulas (1) and (2).

Ry≧1 (1)
θa≧0.7 (2)

In the formula (1), Ry is the maximum height [μm] of the convex portion of the unevenness,
In the equation (2), θa is the average inclination angle [°] of the irregularities.

The manufacturing method of the antiglare film of the present invention,
An antiglare layer (B) forming step of forming the antiglare layer (B) on the light transmissive substrate (A) so as to satisfy the mathematical formulas (1) and (2);
In the antiglare layer (B) forming step, a coating step of applying a coating solution onto the light transmissive base material (A) and drying the applied coating solution to form a coating film. Including a coating film forming step,
In the method for producing an antiglare film of the present invention, the coating liquid contains a resin and a solvent.

The optical member of the present invention is an optical member including the antiglare film of the present invention.

The image display device of the present invention is an image display device including the antiglare film of the present invention or the optical member of the present invention.

According to the present invention, it is possible to provide an antiglare film, an optical member and an image display device in which glare is suppressed.

FIG. 1 is a cross-sectional view showing an example of the antiglare film of the present invention. FIG. 2 is a cross-sectional view showing another example of the antiglare film of the present invention. FIG. 3 is a cross-sectional view showing an example of the antiglare film.

Next, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the following description.

In the antiglare film of the present invention, for example, the antiglare layer (B) may contain fine particles.

In the antiglare film of the present invention, for example, unevenness is formed on the surface of the antiglare layer (B) opposite to the light transmissive substrate (A), and the weight average particle diameter of the fine particles is The thickness may be greater than the maximum thickness of the antiglare layer (B) minus the maximum height of the convex portions of the irregularities.

In the antiglare film of the present invention, for example, the weight average particle size of the fine particles may be in the range of 2 to 10 μm.

In the antiglare film of the present invention, for example, another layer may be further laminated on the surface of the antiglare layer (B) opposite to the light transmissive substrate (A).

The antiglare film of the present invention is, for example, an antiglare film in which an antiglare layer (B) and other layers are laminated on the light transmissive substrate (A) in the above order, and the other layers are The anti-glare film may be characterized in that unevenness is formed on the outermost surface thereof and the unevenness satisfies the following mathematical formulas (1) and (2).

Ry≧1 (1)
θa≧0.7 (2)

In the formula (1), Ry is the maximum height [μm] of the convex portion of the unevenness,
In the equation (2), θa is the average inclination angle [°] of the irregularities.

In the method for producing an antiglare film of the present invention, for example, the antiglare layer (B) forming step may further include a curing step of curing the coating film.

In the method for producing an antiglare film of the present invention, for example, the coating liquid may contain fine particles.

The optical member of the present invention may be, for example, a polarizing plate.

The image display device optical member of the present invention may be, for example, a public information display.

[1. Anti-glare film]
As described above, the antiglare film of the present invention is an antiglare film in which the antiglare layer (B) is laminated on the light transmissive substrate (A), and the antiglare film in the antiglare film is the same. An unevenness is formed on the outermost surface on the layer (B) side, and the unevenness satisfies the following mathematical formulas (1) and (2).

Ry≧1 (1)
θa≧0.7 (2)

In the formula (1), Ry is the maximum height [μm] of the convex portion of the unevenness,
In the equation (2), θa is the average inclination angle [°] of the irregularities.

The cross-sectional view of FIG. 1 shows an example of the structure of the antiglare film of the present invention. As shown in the figure, the antiglare film 10 has an antiglare layer (B) 12 laminated on one surface of a light transmissive substrate (A) 11. The antiglare layer (B) 12 contains fine particles 12b and a thixotropy imparting agent 12c in the resin layer 12a. Irregularities are formed on the outermost surface of the antiglare film (B) 12 side of the antiglare film (the surface of the antiglare layer (B) 12 opposite to the light transmissive substrate (A) 11). There is. The maximum height Ry of the convex portion of the unevenness is 1 μm or more. The average inclination angle θa (not shown) of the irregularities is 0.7° or more. Further, the particle diameter D of the fine particles 12b is larger than the film thickness t obtained by subtracting Ry from the maximum thickness d of the antiglare layer (B). However, FIG. 1 is an example, and the present invention is not limited to this. For example, the antiglare film of the present invention may or may not include the fine particles and the thixotropy imparting agent, respectively. Further, in FIG. 1, the particle diameter D of the fine particles 12b is larger than the film thickness t of the antiglare layer (B), but the present invention is not limited to this.

The cross-sectional view of FIG. 3 shows an example of the constitution of an antiglare film which is not the antiglare film of the present invention. This antiglare film has the maximum height Ry of irregularities of less than 1 μm and the average elevation angle θa (not shown) of irregularities of less than 0.7°, except that the antiglare film of FIG. It is the same as that of the film.

Further, the cross-sectional view of FIG. 2 shows another example of the configuration of the antiglare film of the present invention. As shown in the figure, the antiglare film 10 further has another layer 13 laminated on the surface of the antiglare layer (B) 12 opposite to the light transmissive substrate (A) 11. The other layer 13 is not particularly limited and may be, for example, a low refractive index layer, an antireflection layer, a high refractive index layer, a hard coat layer, an adhesive layer, or the like. Other than this, the structure of the antiglare film 10 of FIG. 2 is the same as that of the antiglare film 10 of FIG. In addition, in FIG. 2, unevenness is formed on the outermost surface of the antiglare film 10 on the antiglare layer (B) 12 side (the surface of the other layer 13 opposite to the light transmissive substrate (A) 11). Has been formed. The maximum height Ry of the convex portion of the unevenness is 1 μm or more. The average inclination angle θa (not shown) of the irregularities is 0.7° or more. The maximum height of the portions other than the light-transmitting substrate (A) 11 (the antiglare layer (B) 12 and the other layer 13) in the antiglare film 10 is represented by d in the figure. In addition, unevenness is formed on the surface of the antiglare layer (B) 12 opposite to the light transmissive substrate (A) 11 (on the side of the other layer 13). The film thickness obtained by subtracting the maximum height Ry′ of the irregularities of the antiglare layer (B) 12 from the maximum thickness d′ of the antiglare layer (B) 12 is represented by t in the figure. As shown, t is equal to d'-Ry' and equal to d-Ry. The particle diameter D of the fine particles 12b is larger than the film thickness t as in the case of FIG. 1, but as described above, the present invention is not limited to this. Further, as in the case of FIG. 1, the antiglare layer (B) 12 may or may not include the fine particles and the thixotropy imparting agent, respectively. The other layer 13 is a single layer in FIG. 2, but may be a plurality of layers. When the other layer 13 does not exist, Ry' is equal to Ry and d'is equal to d, as shown in FIG.

Hereinafter, each of the light transmissive substrate (A), the antiglare layer (B), and the other layer will be described with further examples. In the following, the case where the antiglare layer (B) is an antiglare hard coat layer will be mainly described, but the present invention is not limited thereto.

The light transmissive substrate (A) is not particularly limited, but examples thereof include a transparent plastic film substrate. The transparent plastic film substrate is not particularly limited, but preferably has a visible light transmittance (preferably a light transmittance of 90% or more) and excellent transparency (preferably a haze value of 1% or less). For example, the transparent plastic film substrate described in JP-A-2008-90263 can be mentioned. As the transparent plastic film substrate, one having an optically small birefringence is preferably used. The antiglare film of the present invention can be used, for example, in a polarizing plate as a protective film, and in this case, the transparent plastic film substrate includes triacetyl cellulose (TAC), polycarbonate, acrylic polymer, A film formed of a polyolefin or the like having a cyclic or norbornene structure is preferable. Further, in the present invention, as will be described later, the transparent plastic film substrate may be the polarizer itself. With such a structure, a protective layer made of TAC or the like is not required and the structure of the polarizing plate can be simplified, so that the number of manufacturing steps of the polarizing plate or the image display device can be reduced and the production efficiency can be improved. Further, with such a configuration, the polarizing plate can be made thinner. When the transparent plastic film substrate is a polarizer, the antiglare layer (B) and the antireflection layer (C) serve as protective layers. Further, with such a configuration, the antiglare film also has a function as a cover plate when it is mounted on the surface of the liquid crystal cell, for example.

In the present invention, the thickness of the light transmissive substrate (A) is not particularly limited, but in consideration of workability such as strength and handleability and thin layer property, for example, 10 to 500 μm, 20 to 300 μm. , Or 30 to 200 μm. The refractive index of the light transmissive substrate (A) is not particularly limited. The refractive index is, for example, in the range of 1.30 to 1.80 or 1.40 to 1.70.

In the antiglare film of the present invention, for example, the resin contained in the light transmissive substrate (A) may contain an acrylic resin.

In the antiglare film of the present invention, for example, the light transmissive substrate (A) may be an acrylic film.

As described above, the antiglare film of the present invention has irregularities formed on the outermost surface on the antiglare layer (B) side, and the maximum height Ry of the irregularities is 1 μm or more. The maximum height Ry may be, for example, 1.5 μm or more, and may be, for example, 9 μm or less, 8 μm or less, 7 μm or less, or 6 μm or less. The maximum height Ry may be, for example, 1 to 9 μm, 1 to 8 μm, 1 to 7 μm, or 1.5 to 6 μm. Although Ry is preferably large from the viewpoint of suppressing glare, it is preferably not too large from the viewpoint of haze value described later. In the present invention, the maximum height Ry is a numerical value based on JIS B 0601 (1994 version). The measuring method of Ry is not particularly limited, but it can be measured, for example, by the measuring method described in Examples described later.

In the antiglare film of the present invention, the "outermost surface on the antiglare layer (B) side" is the outermost surface on the antiglare layer (B) side. Specifically, the "outermost surface on the antiglare layer (B) side" is the light-transmitting substrate (A) in the antiglare layer (B) when the other layer is not present (for example, FIG. 1). ) And the opposite surface. In addition, the “outermost surface on the antiglare layer (B) side” means that, when the other layer is present (for example, FIG. 2 ), the outermost surface on the side opposite to the light transmissive substrate (A) in the other layer. The outer surface.

In the antiglare film of the present invention, as described above, the average inclination angle θa (°) is 0.7 or more in the uneven shape of the outermost surface on the antiglare layer (B) side. The average inclination angle θa may be, for example, 0.7° or more, 0.8° or more, 0.9° or more, or 1.0° or more, and 8° or less, 7° or less, 6° or less. , Or 5° or less. The average inclination angle θa is, for example, 0.7 to 8°, 0.7 to 7°, 0.7 to 6°, 0.7 to 5°, 0.8 to 8°, 0.8 to 7°. , 0.8-6°, 0.8-5°, 0.9-8°, 0.9-7°, 0.9-6°, 0.9-5°, 1.0-8°, It may be 1.0-7°, 1.0-6°, or 1.0-5°. From the viewpoint of suppressing glare, θa is preferably large, but from the viewpoint of haze value described later, it is preferably not too large. Here, the average tilt angle θa is a value defined by the following mathematical expression (3). The average inclination angle θa can be measured, for example, by the method described in Examples below.

Average inclination angle θa=tan ⁻¹ Δa (3)

In the mathematical expression (3), Δa is, as shown in the following mathematical expression (4), the sum of the peaks and valleys of the adjacent peaks in the reference length L of the roughness curve defined in JIS B 0601 (1994 version). It is a value obtained by dividing the total (h1+h2+h3... +hn) of the difference (height h) from the lowest point by the reference length L. The roughness curve is a curve obtained by removing a surface waviness component longer than a predetermined wavelength from a cross-section curve by a phase difference compensation type high-pass filter. Further, the cross-sectional curve is a contour that appears at the cut when the target surface is cut by a plane perpendicular to the target surface.

Δa=(h1+h2+h3...+hn)/L (4)

The antiglare film of the present invention may have a haze value of, for example, 4% or more, 6% or more, 10% or more, or 15% or more, for example, 50% or less, 40% or less, It may be 35% or less, or less than 30%. The haze value may be, for example, 4 to 50%, 6 to 40%, 10 to 40%, further 15 to 40%, or 15 to 35%. The haze value is a haze value (cloudiness) of the entire antiglare film according to JIS K 7136 (2000 version). Generally, in the antiglare film, when the haze value is large, it is easy to suppress glare. However, if the haze value is too large, the display characteristics are likely to be deteriorated such that the image becomes unclear and the contrast in the dark is lowered. However, according to the present invention, when Ry and θa satisfy the mathematical expressions (1) and (2), the haze value is, for example, 50% or less, 40% or less, 35% or less, or less than 30%. Even if it is small, the reflection can be suppressed. In addition, in order to make the haze value as small as possible, in addition to the adjustment of Ry and θa, the refractive index difference between the resin and the fine particles to be described later is made as small as possible (for example, in the range of 0.001 to 0.02). The fine particles and the resin may be selected.

In the antiglare film of the present invention, for example, the antiglare layer (B) may contain a resin and a filler. The filler may include at least one of fine particles and a thixotropic agent.

In the antiglare film of the present invention, for example, the resin contained in the antiglare layer (B) may contain an acrylate resin (also referred to as an acrylic resin).

In the antiglare film of the present invention, for example, the resin contained in the antiglare layer (B) may contain a urethane acrylate resin.

In the antiglare film of the present invention, for example, the resin contained in the antiglare layer (B) may be a copolymer of a curable urethane acrylate resin and a polyfunctional acrylate.

In the antiglare film of the present invention, for example, the antiglare layer (B) is formed using an antiglare layer forming material containing a resin and a filler, and the antiglare layer (B) contains the filler. The antiglare layer (B) may have an aggregating portion that forms a convex portion by aggregating. In addition, in the aggregating portion forming the convex portion, a plurality of the fillers may be present in a state gathered in one direction in the surface direction of the antiglare layer (B). In the image display device of the present invention, for example, the antiglare film of the present invention may be arranged such that one direction in which a plurality of the fillers are gathered and a long side direction of the black matrix pattern match. ..

In the antiglare film of the present invention, the thixotropy-imparting agent may be at least one selected from the group consisting of organic clay, oxidized polyolefin and modified urea. Further, the thixotropy imparting agent may be, for example, a thickener.

In the antiglare film of the present invention, for example, the thixotropy-imparting agent may be contained in the range of 0.2 to 5 parts by weight with respect to 100 parts by weight (mass) of the resin in the antiglare layer (B). Good.

In the antiglare film of the present invention, the fine particles are contained in the range of, for example, 0.2 to 12 parts by weight or 0.5 to 12 parts by weight with respect to 100 parts by weight of the resin of the antiglare layer (B). It may be.

In the method for producing an antiglare film of the present invention, the surface shape of the antiglare film is further adjusted by adjusting the number of parts by weight of the fine particles relative to 100 parts by weight of the resin in the material for forming an antiglare layer. May be.

The antiglare layer (B) is applied, for example, by coating a coating liquid containing the resin, the filler and a solvent on at least one surface of the light transmissive substrate (A) as described below. It is formed by forming a film and then removing the solvent from the coating film. Examples of the resin include a thermosetting resin and an ionizing radiation curable resin that is cured by ultraviolet rays or light. As the resin, it is also possible to use a commercially available thermosetting resin, ultraviolet curable resin, or the like.

As the thermosetting resin or the ultraviolet curable resin, for example, a curable compound having at least one group of an acrylate group and a methacrylate group that is cured by heat, light (such as ultraviolet rays) or an electron beam can be used. Silicone resins, polyester resins, polyether resins, epoxy resins, urethane resins, alkyd resins, spiro acetal resins, polybutadiene resins, polythiol polyene resins, oligomers or prepolymers of polyfunctional compounds such as polyhydric alcohols such as acrylate and methacrylate. can give. These may be used alone or in combination of two or more.

For the resin, for example, a reactive diluent having at least one of an acrylate group and a methacrylate group can be used. As the reactive diluent, for example, the reactive diluent described in JP-A-2008-88309 can be used, and examples thereof include monofunctional acrylate, monofunctional methacrylate, polyfunctional acrylate, and polyfunctional methacrylate. As the reactive diluent, trifunctional or higher functional acrylate and trifunctional or higher functional methacrylate are preferable. This is because the hardness of the antiglare layer (B) can be made excellent. Examples of the reactive diluent also include butanediol glycerin ether diacrylate, acrylate of isocyanuric acid, and methacrylate of isocyanuric acid. These may be used alone or in combination of two or more.

The fine particles for forming the antiglare layer (B) impart unevenness to the surface of the formed antiglare layer (B) to impart antiglare property, and further, the haze value of the antiglare layer (B) is changed. The main function is to control. The haze value of the antiglare layer (B) can be designed by controlling the refractive index difference between the fine particles and the resin. Examples of the fine particles include inorganic fine particles and organic fine particles. The inorganic fine particles are not particularly limited and include, for example, silicon oxide particles, titanium oxide particles, aluminum oxide particles, zinc oxide particles, tin oxide particles, calcium carbonate particles, barium sulfate particles, talc particles, kaolin particles, calcium sulfate particles and the like. Can be given. The organic fine particles are not particularly limited, and examples thereof include polymethylmethacrylate resin powder (PMMA particles), silicone resin powder, polystyrene resin powder, polycarbonate resin powder, acrylic styrene resin powder, benzoguanamine resin powder, melamine resin powder, and polyolefin. Examples thereof include resin powder, polyester resin powder, polyamide resin powder, polyimide resin powder, polyfluorinated ethylene resin powder and the like. These inorganic fine particles and organic fine particles may be used alone or in combination of two or more.

The particle diameter (D) (weight average particle diameter) of the fine particles is not particularly limited, but is, for example, in the range of 2 to 10 μm. By setting the weight average particle diameter of the fine particles within the above range, for example, an antiglare film having more excellent antiglare properties and suppressed glare can be obtained. From the viewpoint of suppressing reflection from an oblique direction, it is preferable that the weight average particle diameter of the fine particles is not too small. From the viewpoint of suppressing reflection from the front direction, it is preferable that the weight average particle diameter of the fine particles is not too large. The weight average particle diameter of the fine particles may be, for example, 2 μm or more or 3 μm or more, and may be, for example, 10 μm or less, 9 μm or less, or 8 μm or less. The weight average particle diameter of the fine particles may be, for example, 2 to 10 μm, 2 to 9 μm, or 3 to 8 μm. The weight average particle size of the fine particles can be measured, for example, by the Coulter counting method. For example, using a particle size distribution measuring device (trade name: Coulter Multisizer, manufactured by Beckman Coulter, Inc.) using the pore electrical resistance method, an electrolyte solution corresponding to the volume of the fine particles when the fine particles pass through the fine holes is used. By measuring the electric resistance, the number and volume of the fine particles are measured, and the weight average particle diameter is calculated.

The shape of the fine particles is not particularly limited, and may be, for example, a bead-like substantially spherical shape, or an irregular shape such as powder, but a substantially spherical shape is preferable, and an aspect is more preferable. The particles are substantially spherical particles having a ratio of 1.5 or less, and most preferably spherical particles.

The content of the fine particles in the antiglare layer (B) is not particularly limited, and can be set appropriately in consideration of, for example, the surface shape of the antiglare layer (B). The relationship between the content of the fine particles (parts by weight with respect to the resin) and the weight average particle diameter, and the surface shape of the antiglare layer (B) will be described later.

In the antiglare layer (B), the filler may be fine particles and a thixotropy imparting agent. The thixotropy-imparting agent may be contained alone or, in addition to the fine particles, may further contain the thixotropy-imparting agent. By including the thixotropy-imparting agent, it is possible to easily control the aggregation state of the fine particles. Examples of the thixotropy imparting agent include organic clay, polyolefin oxide, and modified urea.

The organic clay is preferably an organically treated layered clay in order to improve the affinity with the resin. The organoclay may be prepared in-house or a commercially available product may be used. Examples of the commercially available products include Lucentite SAN, Lucentite STN, Lucentite SEN, Lucentite SPN, Someriff ME-100, Someriff MAE, Someriff MTE, Someriff MEE, Someriff MPE (trade names, all are Corp Chemical Co., Ltd. Manufactured); Sven, Sven C, Sven E, Sven W, Sven P, Sven WX, Sven N-400, Sven NX, Sven NX80, Sven NO12S, Sven NEZ, Sven NO12, Sven NE, Sven NZ, Sven NZ70, Olga Knight, Organite D, Organite T (trade name, all manufactured by Hojun Co., Ltd.); Kunipia F, Kunipia G, Kunipia G4 (trade name, all manufactured by Kunimine Industry Co., Ltd.); Thixogel VZ, Clayton HT, Clayton 40 (Trade names, all manufactured by Rockwood Additives, Inc.) and the like.

The oxidized polyolefin may be prepared in-house or a commercially available product may be used. Examples of the commercially available products include Disparlon 4200-20 (trade name, manufactured by Kusumoto Kasei Co., Ltd.), Flownon SA300 (trade name, manufactured by Kyoeisha Chemical Co., Ltd.), and the like.

The modified urea is a reaction product of an isocyanate monomer or an adduct thereof with an organic amine. The modified urea may be prepared in-house or a commercially available product may be used. Examples of the commercially available product include BYK410 (manufactured by Big Chemie).

The thixotropy-imparting agents may be used alone or in combination of two or more.

The proportion of the thixotropy imparting agent in the antiglare layer (B) is preferably 0.2 to 5 parts by weight, more preferably 0.4 to 4 parts by weight, based on 100 parts by weight of the resin. is there.

The maximum thickness (d') of the antiglare layer (B) is not particularly limited, but is preferably in the range of 3 to 12 µm. By setting the maximum thickness (d′) of the antiglare layer (B) within the above range, for example, it is possible to prevent the occurrence of curl in the antiglare film and reduce the productivity such as poor transportability. Can be avoided. Further, when the thickness (d) is in the above range, the weight average particle diameter (D) of the fine particles is preferably in the range of 2 to 10 μm as described above. When the maximum thickness (d′) of the antiglare layer (B) and the weight average particle diameter (D) of the fine particles are in the above combination, an antiglare film having excellent antiglare properties can be obtained. it can. The maximum thickness (d′) of the antiglare layer (B) is more preferably within the range of 3 to 8 μm.

The ratio D/d′ between the thickness (d′) of the antiglare layer (B) and the weight average particle diameter (D) of the fine particles is, for example, 1 or less, less than 1, less than 0.98, 0.96 or less. , 0.93 or less, or 0.90 or less, and 0.5 or more, 0.6 or more, 0.7 or more, or 0.8 or more. By having such a relationship, it is possible to obtain an antiglare film which is more excellent in the antiglare property and in which glare is suppressed. For example, when D/d' is large, Ry and θa tend to be large.

In the antiglare film of the present invention, for example, the antiglare layer (B) has an aggregated portion that forms a convex portion on the surface of the antiglare layer (B) due to aggregation of the filler. However, in the agglomerated portion forming the convex portion, a plurality of the fillers may be present in a state gathered in one direction in the plane direction of the antiglare layer (B). Thereby, for example, the reflection of a fluorescent lamp can be prevented. However, the antiglare film of the present invention is not limited to this.

The surface shape of the antiglare layer (B) is, for example, a film thickness t obtained by subtracting the maximum height Ry′ of the irregularities of the antiglare layer (B) from the maximum thickness d′ of the antiglare layer (B), It can be designed by adjusting the weight average particle diameter D of the fine particles. Specifically, for example, when the weight average particle diameter D of the fine particles is relatively large with respect to the film thickness t of the antiglare layer (B), Ry and θa are likely to be large. The film thickness t can be adjusted by the coating thickness of the resin, for example. The surface shape of the antiglare layer (B) can also be designed by adjusting the number of parts by weight of the fine particles with respect to 100 parts by weight of the resin in the antiglare layer forming material. For example, when the number of parts by weight of the fine particles is relatively large relative to the resin, θa tends to increase.

Further, the antiglare film of the present invention includes, for example, a resin derived from the light transmissive substrate (A) between the light transmissive substrate (A) and the antiglare layer (B), and It may have an intermediate layer containing a resin derived from the antiglare layer (B). By controlling the thickness of the intermediate layer, the surface shape of the antiglare layer (B) can be controlled. For example, if the thickness of the intermediate layer is increased, the Ry and θa are likely to be increased, and if the thickness of the intermediate layer is reduced, the Ry and θa are easily reduced.

In the present invention, the mechanism by which the intermediate layer (also referred to as a permeation layer or a compatible layer) is formed is not particularly limited, but for example, it is formed in the drying step in the method for producing an antiglare hard coat film of the present inventor. To be done. Specifically, for example, in the drying step, the coating liquid for forming the antiglare layer (B) penetrates into the light transmissive base material (A), and is derived from the light transmissive base material (A). The intermediate layer containing a resin and a resin derived from the antiglare layer (B) is formed. The resin contained in the intermediate layer is not particularly limited, and for example, the resin contained in the light transmissive substrate (A) and the resin contained in the antiglare layer (B) are simply mixed (compatible). It may be a thing. Further, the resin contained in the intermediate layer is, for example, at least one of the resin contained in the light transmissive substrate (A) and the resin contained in the antiglare layer (B) is heating, light irradiation, or the like. It may be chemically changed by.

The thickness ratio R of the intermediate layer defined by the following mathematical formula (5) is not particularly limited, but is, for example, 0.10 to 0.80, for example, 0.15 or more, 0.20 or more, 0.25. It may be 0.30 or more, 0.40 or more, or 0.45 or more, and for example, 0.75 or less, 0.70 or less, 0.65 or less, 0.60 or less, 0.50 or less, It may be 0.40 or less, 0.45 or less, or 0.30 or less. The thickness ratio R of the intermediate layer is, for example, 0.15 to 0.75, 0.20 to 0.70, 0.25 to 0.65, 0.30 to 0.60, 0.40 to 0.50. , 0.45-0.50, 0.15-0.45, 0.15-0.40, 0.15-0.30, or 0.20-0.30. The intermediate layer can be confirmed, for example, by observing the cross section of the antiglare hard coat film with a transmission electron microscope (TEM), and the thickness can be measured.

R=[D _C /(D _C +D _B )] (5)

In the mathematical expression (5), D _B is the thickness [μm] of the antiglare layer (B), and D _C is the thickness [μm] of the intermediate layer.

The surface shape of the antiglare layer (B) can also be designed by controlling the aggregation state of the filler contained in the antiglare layer forming material. The aggregation state of the filler can be controlled by, for example, the material of the filler (for example, the chemically modified state of the surface of the fine particles, the affinity for the solvent or the resin, etc.), the type (combination) or combination of the resin (binder) or the solvent. Moreover, the aggregation state of the fine particles can be precisely controlled by the thixotropy imparting agent.

The anti-glare film of the present invention may be one in which the convex portion has a gentle shape and can prevent generation of protrusions on the surface of the anti-glare layer (B), which is a defect in appearance. It is not limited to this. In the antiglare film of the present invention, the fine particles may be present to some extent, for example, at a position directly or indirectly overlapping the thickness direction of the antiglare layer (B).

The other layer is not particularly limited and may be, for example, a low refractive index layer, an antireflection layer, a high refractive index layer, a hard coat layer, a pressure-sensitive adhesive layer, or the like, as described above. Further, the other layer may be a single layer or a plurality of layers, and in the case of a plurality of layers, one kind or plural kinds may be used. For example, the other layer may be an optical thin film whose thickness and refractive index are strictly controlled, or a laminate of two or more layers of the optical thin films.

[2. Manufacturing method of antiglare film]
The method for producing the antiglare film of the present invention is not particularly limited and may be produced by any method, but it is preferably produced by the method for producing the antiglare film of the present invention.

The method for producing the antiglare film can be performed, for example, as follows.

First, the antiglare layer (B) is formed on the light transmissive substrate (A) so as to satisfy the mathematical expressions (1) and (2) (antiglare layer (B) forming step). In this way, a laminate of the light transmissive substrate (A) and the antiglare layer (B) is manufactured. As described above, the antiglare layer (B) forming step includes a coating step of applying the coating solution onto the light-transmitting substrate (A), and a step of drying the applied coating solution to apply the coating solution. A coating film forming step of forming a film. Further, for example, as described above, the antiglare layer (B) forming step may further include a curing step of curing the coating film. The curing can be performed, for example, after the drying, but is not limited thereto. The curing can be performed, for example, by heating, light irradiation or the like. The light is not particularly limited, but may be, for example, ultraviolet light. The light source for the light irradiation is not particularly limited, but may be, for example, a high pressure mercury lamp or the like.

As described above, the coating liquid contains the resin and the solvent. The coating liquid may be, for example, an antiglare layer forming material (coating liquid) containing the resin, the particles, the thixotropy imparting agent, and the solvent.

The coating liquid preferably exhibits thixotropy, and the Ti value defined by the following formula is preferably in the range of 1.3 to 3.5, more preferably 1.4 to 3. It is in the range of 2, and more preferably in the range of 1.5 to 3.

Ti value=β1/β2

In the above formula, β1 is a viscosity measured under the condition of shear rate 20 (1/s) using HAAKE RheoStress RS6000, and β2 is shear rate 200 (1/s) using HAAKE Rheostress RS6000. The viscosity is measured under the conditions of.

When the Ti value is 1.3 or more, problems such as appearance defects and deterioration of antiglare properties and white blur characteristics are less likely to occur. Further, if the Ti value is 3.5 or less, problems such as the particles being in a dispersed state without aggregating are unlikely to occur.

Further, the coating liquid may or may not contain a thixotropy-imparting agent, but it is preferable to contain the thixotropy-imparting agent because the thixotropy is easily exhibited. In addition, as described above, the effect of preventing sedimentation of the particles (thixotropic effect) can be obtained because the coating liquid contains the thixotropy imparting agent. Furthermore, the surface shape of the antiglare film can be freely controlled in a wider range by shear aggregation of the thixotropy imparting agent itself.

The solvent is not particularly limited and various solvents can be used, and one kind may be used alone, or two or more kinds may be used in combination. In order to obtain the antiglare film of the present invention, the optimum solvent type and solvent ratio may be appropriately selected depending on the composition of the resin, the type and content of the particles and the thixotropy imparting agent. The solvent is not particularly limited, but examples thereof include alcohols such as methanol, ethanol, isopropyl alcohol (IPA), butanol, t-butyl alcohol (TBA), and 2-methoxyethanol; acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclopenta. Ketones such as NON; esters such as methyl acetate, ethyl acetate and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; Aliphatic hydrocarbons such as hexane, heptane and octane; aromatic hydrocarbons such as benzene, toluene and xylene. Further, for example, the solvent may include a hydrocarbon solvent and a ketone solvent. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene. The ketone solvent may be, for example, cyclopentanone, and at least one selected from the group consisting of acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The solvent preferably contains the hydrocarbon solvent (eg, toluene) in order to dissolve, for example, a thixotropy-imparting agent (eg, thickener). The solvent may be, for example, a solvent obtained by mixing the hydrocarbon solvent and the ketone solvent in a mass ratio of 90:10 to 10:90. The mass ratio of the hydrocarbon solvent and the ketone solvent may be, for example, 80:20 to 20:80, 70:30 to 30:70, or 40:60 to 60:40. In this case, for example, the hydrocarbon solvent may be toluene and the ketone solvent may be methyl ethyl ketone. Further, the solvent may include, for example, toluene and further at least one selected from the group consisting of ethyl acetate, butyl acetate, IPA, methyl isobutyl ketone, methyl ethyl ketone, methanol, ethanol, and TBA. Good.

As the light-transmissive substrate (A), for example, when an acrylic film is used to form the intermediate layer (penetration layer), a good solvent for the acrylic film (acrylic resin) can be preferably used. The solvent may be, for example, a solvent containing a hydrocarbon solvent and a ketone solvent as described above. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene. The ketone solvent may be at least one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The solvent may be, for example, a solvent obtained by mixing the hydrocarbon solvent and the ketone solvent in a mass ratio of 90:10 to 10:90. The mass ratio of the hydrocarbon solvent and the ketone solvent may be, for example, 80:20 to 20:80, 70:30 to 30:70, or 40:60 to 60:40. In this case, for example, the hydrocarbon solvent may be toluene and the ketone solvent may be methyl ethyl ketone.

For example, when triacetyl cellulose (TAC) is used as the light-transmitting substrate (A) to form the intermediate layer (permeation layer), a good solvent for TAC can be preferably used. Examples of the solvent include ethyl acetate, methyl ethyl ketone, cyclopentanone and the like.

Further, by properly selecting the solvent, the thixotropy of the material for forming an antiglare layer (coating liquid) can be satisfactorily exhibited when the thixotropy-imparting agent is contained. For example, when an organic clay is used, toluene and xylene can be preferably used alone or in combination. For example, when an oxidized polyolefin is used, methyl ethyl ketone, ethyl acetate, and propylene glycol monomethylmatel are preferably used alone. They can be used or used together. For example, when a modified urea is used, butyl acetate and methyl isobutyl ketone are preferably used alone or in combination.

Various leveling agents can be added to the antiglare layer forming material. As the leveling agent, for example, a fluorine-based or silicone-based leveling agent can be used for the purpose of preventing coating unevenness (uniformizing the coated surface). In the present invention, when antifouling property is required on the surface of the antiglare layer (B), or as described later, the antireflection layer (low refractive index layer) or the layer containing the interlayer filler is on the antiglare layer (B). The leveling agent can be appropriately selected according to the case where the leveling agent is formed. In the present invention, for example, by containing the thixotropy-imparting agent, the coating liquid can be made to exhibit thixotropy, and thus coating unevenness is unlikely to occur. In this case, for example, there is an advantage that the choice of the leveling agent can be expanded.

The compounding amount of the leveling agent is, for example, 5 parts by weight or less, and preferably 0.01 to 5 parts by weight with respect to 100 parts by weight of the resin.

To the antiglare layer forming material, if necessary, a pigment, a filler, a dispersant, a plasticizer, an ultraviolet absorber, a surfactant, an antifouling agent, an antioxidant, etc. are added within a range that does not impair the performance. May be done. These additives may be used alone or in combination of two or more.

As the material for forming the antiglare layer, for example, a conventionally known photopolymerization initiator as described in JP-A-2008-88309 can be used.

Examples of the method for forming the coating film by coating the coating liquid on the light transmissive substrate (A) include, for example, a fan-ten coating method, a die coating method, a spin coating method, a spray coating method, and a gravure coating method. A coating method such as a roll coating method or a bar coating method can be used.

Next, as described above, the coating film is dried and cured to form the antiglare layer (B). The drying may be, for example, natural drying, air drying by blowing air, heat drying, or a combination thereof.

The drying temperature of the coating liquid for forming the antiglare layer (B) may be, for example, in the range of 30 to 200°C. The drying temperature may be, for example, 40°C or higher, 50°C or higher, 60°C or higher, 70°C or higher, 80°C or higher, 90°C or higher, or 100°C or higher, and 190°C or lower, 180°C or lower, 170. C. or lower, 160.degree. C. or lower, 150.degree. C. or lower, 140.degree. C. or lower, 135.degree. C. or lower, 130.degree. C. or lower, 120.degree. C. or lower, or 110.degree. C. or lower. The drying time is not particularly limited, but may be, for example, 30 seconds or more, 40 seconds or more, 50 seconds or more, or 60 seconds or more, and is 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less. May be.

The means for curing the coating film is not particularly limited, but UV curing is preferred. The irradiation amount of the energy ray source is preferably 50 to 500 mJ/cm ² as an integrated exposure amount at an ultraviolet wavelength of 365 nm. When the irradiation amount is 50 mJ/cm ² or more, curing is likely to proceed sufficiently and the hardness of the antiglare layer (B) to be formed tends to be high. Further, when it is 500 mJ/cm ² or less, coloring of the formed antiglare layer (B) can be prevented.

As described above, a laminate of the light transmissive substrate (A) and the antiglare layer (B) can be manufactured. This laminate may be used as the antiglare film of the present invention as it is, or for example, the other layer may be formed on the antiglare layer (B) to form the antiglare film of the present invention. The method for forming the other layer is not particularly limited, and is, for example, the same as or similar to the method for forming a general low refractive index layer, antireflection layer, high refractive index layer, hard coat layer, pressure-sensitive adhesive layer, or the like. Can be done at.

[3. Optical member and image display device]
The optical member of the present invention is not particularly limited, but may be, for example, a polarizing plate. The polarizing plate is also not particularly limited, but may include, for example, the antiglare film and the polarizer of the present invention, and may further include other constituent elements. The respective constituent elements of the polarizing plate may be attached to each other with, for example, an adhesive or a pressure-sensitive adhesive.

The image display device of the present invention is not particularly limited, and any image display device may be used, and examples thereof include a liquid crystal display device and an organic EL display device.

The image display device of the present invention is, for example, an image display device having the antiglare film of the present invention on the viewing side surface, and the image display device may have a black matrix pattern.

In the antiglare film of the present invention, for example, the light transmissive substrate (A) side can be attached to an optical member used in an LCD via an adhesive or an adhesive. In addition, at the time of this bonding, the above-mentioned various surface treatments may be performed on the surface of the light transmissive substrate (A). As described above, according to the method for producing an antiglare film of the present invention, the surface shape of the antiglare film can be freely controlled in a wide range. Therefore, the optical properties that can be obtained by laminating the antiglare film with another optical member using an adhesive, a pressure sensitive adhesive, etc., cover a wide range corresponding to the surface shape of the antiglare film. ..

Examples of the optical member include a polarizer and a polarizing plate. The polarizing plate generally has a structure having a transparent protective film on one side or both sides of the polarizer. When the transparent protective films are provided on both sides of the polarizer, the transparent protective films on the front and back may be made of the same material or different materials. Polarizing plates are usually arranged on both sides of the liquid crystal cell. Further, the polarizing plates are arranged so that the absorption axes of the two polarizing plates are substantially orthogonal to each other.

The configuration of the polarizing plate laminated with the antiglare film is not particularly limited, for example, a configuration in which a transparent protective film, the polarizer and the transparent protective film are laminated in this order on the antiglare film. Alternatively, the polarizer and the transparent protective film may be laminated in this order on the antiglare film.

The image display device of the present invention has the same configuration as a conventional image display device except that the antiglare film is arranged in a specific direction. For example, in the case of an LCD, it can be manufactured by appropriately assembling a liquid crystal cell, optical members such as a polarizing plate, and each component such as an illumination system (backlight or the like) and a drive circuit as necessary.

According to the antiglare film of the present invention, for example, strong external light can be scattered and reflection can be suppressed, so that glare can be suppressed even outdoors. Therefore, the image display device of the present invention can be suitably used, for example, as an outdoor public information display. However, the image display device of the present invention is not limited to this application and can be used for any other application. Examples of applications include personal computer monitors, notebook computers, copiers, and other OA devices, mobile phones, watches, digital cameras, personal digital assistants (PDAs), portable game devices and other portable devices, video cameras, televisions, and microwave ovens. Household electrical equipment such as, back monitors, car navigation system monitors, car audio equipment, in-vehicle equipment, commercial store information monitors and other display equipment, surveillance monitors and other security equipment, nursing monitors, medical monitors Nursing care and medical equipment, etc.

Next, examples of the present invention will be described together with comparative examples. However, the present invention is not limited by the following examples and comparative examples.

In the following examples and comparative examples, the number of parts of a substance is part by weight (part by weight) unless otherwise specified.

<Production Example 1> Production of substrate film A First, in the same manner as in Production Example 1 of JP2010-284840A, imidization was performed using a tandem reaction extruder in which two extrusion reactors were arranged in series. A polymethylmethacrylate resin was produced. As the tandem type reactive extruder, a first-direction extruder and a second-direction extruder were used, and the same direction meshing twin-screw extruder having a diameter of 75 mm and an L/D (ratio of the length L of the extruder to the diameter D) of 74 was used. .. A constant weight feeder (manufactured by Kubota Corporation) was used to supply the raw material resin to the first extruder raw material supply port. The degree of pressure reduction of each vent in the first extruder and the second extruder was set to -0.095 MPa. A pipe having a diameter of 38 mm and a length of 2 m was used for connecting the first extruder and the second extruder. A constant flow pressure valve was used for the internal pressure control mechanism for connecting the resin discharge port of the first extruder and the raw material supply port of the second extruder. Further, a resin pressure gauge was provided at each of the outlet of the first extruder, the central portion of the connecting part between the first extruder and the second extruder, and the outlet of the second extruder. This resin pressure gauge can be used for adjusting the pressure in the component connecting the resin discharge port of the first extruder and the second extruder raw material supply port, or for determining the extrusion fluctuation.

The imidized polymethylmethacrylate resin was produced as follows. First, the raw material resin polymethylmethacrylate resin (Mw: 105,000) and the imidizing agent monomethylamine were charged into the first extruder to produce the imide resin intermediate 1. At this time, the extruder maximum temperature was 280° C., the screw rotation speed was 55 rpm, the raw material resin supply rate was 150 kg/hour, and the addition amount of monomethylamine was 2.0 parts with respect to 100 parts of the raw material resin. Further, the pressure of the first extruder monomethylamine press-fitting section was adjusted to 8 MPa by the constant flow pressure valve installed immediately before the second extruder raw material supply port. Next, the imide resin intermediate body 1 was transferred into the second extruder, and the remaining imidization reaction reagent and by-products were devolatilized by the rear vent and the vacuum vent. Then, a mixed solution of dimethyl carbonate and triethylamine was added as an esterifying agent to produce an imide resin intermediate 2. At this time, the barrel temperature of the second extruder was 260° C., the screw rotation speed was 55 rpm, the addition amount of dimethyl carbonate was 3.2 parts with respect to 100 parts of the raw material resin, and the addition amount of triethylamine was with respect to 100 parts of the raw material resin. To 0.8. Further, after removing the esterifying agent with a vent, it was extruded from a strand die, cooled in a water tank, and then pelletized with a pelletizer to obtain an imidized poly(methyl methacrylate) resin. The imidation ratio of this imidized polymethylmethacrylate resin was 3.7%, and the acid value was 0.29 mmol/g.

Next, 100 parts by weight of the imidized polymethylmethacrylate resin and 0.62 parts by weight of a triazine-based ultraviolet absorber (trade name: T-712 manufactured by ADEKA CORPORATION) are mixed at 220° C. in a biaxial kneader. Then, resin pellets were prepared. The resin pellets were dried at 100.5 kPa and 100° C. for 12 hours, and extruded from a T die at a die temperature of 270° C. with a single screw extruder to form a film (thickness 160 μm). Further, the film was stretched in the transport direction of the film in an atmosphere of 150° C. to have a thickness of 80 μm. Next, the film was stretched in a direction orthogonal to the transport direction of the film under an atmosphere of 150° C. to obtain a base film A ((meth)acrylic resin film) having a thickness of 40 μm. The transmittance of light having a wavelength of 380 nm of the obtained base film A was 8.5%, the in-plane retardation Re was 0.4 nm, and the thickness direction retardation Rth was 0.78 nm. The moisture permeability of the obtained base film A was 61 g/m ² ·24 hr. The light transmittance was measured with a spectrophotometer (device name: U-4100) manufactured by Hitachi High-Tech Co., Ltd. in a wavelength range of 200 nm to 800 nm, and the transmittance at a wavelength of 380 nm was read. .. Moreover, the phase difference value was measured at a wavelength of 590 nm and 23° C. by using a product name “KOBRA21-ADH” manufactured by Oji Scientific Instruments. The water vapor permeability was measured by a method according to JIS K 0208 under the conditions of a temperature of 40° C. and a relative humidity of 92%.

[Coating liquid 1]
Pentaerythritol triacrylate (PETA) (Osaka Organic Chemical Industry Co., Ltd., trade name: viscoat #300, concentration 80%) 60 parts, 15-functional urethane acrylic oligomer (Shin Nakamura Chemical Co., Ltd., trade name: NK Oligo UA-53H, Weight average molecular weight: 2300, concentration 100%) 40 parts, 4-hydroxybutyl acrylate (Osaka Organic Chemical Co., Ltd., trade name: 4-HBA, concentration 100%) 20 parts, leveling agent (DIC, trade name: GRANDIC PC-4100) 1 part, photopolymerization initiator (manufactured by BASF Japan, trade name: Irgacure 907) 5 parts, fine particles of crosslinked acrylic styrene copolymer resin (manufactured by Sekisui Kasei Co., trade name: SSX1055QXE, weight average particle) Diameter: 5.5 μm) 8 parts, thickener (thixotropic agent, manufactured by Kunimine Industries Co., Ltd., trade name: smecton SAN adjusted to a concentration of 6% with toluene) 2.5 parts and mixed to obtain a solid content. A concentration of 40% and a total amount of toluene and methyl ethyl ketone were diluted to 7:3 to prepare coating liquid 1 (composition for forming an antiglare layer).

[Coating liquid 2]
Coating liquid 1 was coated in the same manner as coating liquid 1 except that the fine particles of the crosslinked acrylic styrene copolymer resin of coating liquid 1 were changed to 6 parts of the fine particles of the crosslinked acrylic styrene copolymer resin having a weight average particle diameter of 3.0 μm. Working liquid 2 (composition for forming an antiglare layer) was prepared.

[Coating liquid 3]
Coating liquid 1 was coated in the same manner as coating liquid 1 except that the fine particles of crosslinked acrylic styrene copolymer resin of coating liquid 1 were changed to 20 parts of fine particles of crosslinked acrylic styrene copolymer resin having a weight average particle diameter of 8.0 μm. Working solution 3 (composition for forming an antiglare layer) was prepared.

<Measurement method>
[Surface shape measurement]
A glass plate (thickness: 1.3 mm) manufactured by Matsunami Glass Industry Co., Ltd. is attached to the surface of the anti-glare film on which the anti-glare layer is not formed, with a high-precision fine shape measuring instrument (trade name: Surf). The surface shape of the antiglare layer (B) was measured using a coder ET4000, manufactured by Kosaka Laboratory Ltd. under the condition of a cutoff value of 0.8 mm, and the maximum height and the average inclination angle were calculated. Furthermore, the average values obtained by measuring the maximum height and the average inclination angle at arbitrary 10 points were taken as the maximum height Ry and the average inclination angle θa, respectively. The high-precision fine shape measuring instrument automatically calculates the maximum height Ry and the average inclination angle θa. The measuring method and the calculating method of the maximum height Ry and the average inclination angle θa are based on JIS B 0601 (1994 version).

[Reflection]
(1) A black acrylic plate (manufactured by Mitsubishi Rayon Co., Ltd., thickness 2.0 mm) was attached to the surface of the anti-glare film on which the anti-glare layer was not formed with an adhesive to remove the reflection on the back surface of the sample. It was made.
(2) Generally, in an office environment (about 1000 Lx) using a display, the sample was illuminated with a fluorescent lamp (three-wavelength light source), and the antiglare property of the sample was visually determined according to the following criteria.

Judgment Criteria ◯: Excellent anti-glare property, and does not leave an image of the contour of the fluorescent lamp reflected in
Δ: The antiglare property is inferior to that of ◯, but it is possible to prevent glare without problems.
×: The outline of the fluorescent lamp is not blurred and is clearly reflected.

[Film thickness t]
The maximum thickness of the antiglare layer (B) is measured at the same 10 points as the measurement point of the maximum height Ry by using the high precision fine shape measuring instrument (trade name; Surfcoder ET4000, manufactured by Kosaka Laboratory Ltd.). did. The average value of the measured values of the maximum thickness at the 10 points was defined as the maximum thickness d of the antiglare layer (B). A value obtained by subtracting the maximum height Ry from the maximum thickness d was defined as the film thickness t of the antiglare layer (B). The high-precision fine shape measuring instrument automatically calculates the maximum thickness d and the film thickness t. Further, in the present example and the comparative example, since the maximum thickness d is substantially equal to the weight average particle diameter of the fine particles, the numerical value obtained by subtracting the maximum height Ry from the weight average particle diameter is approximately referred to as the film thickness t. can do.

[Haze value]
The haze value is measured in accordance with JIS K 7136 (2000 version) haze (cloudiness) using a haze meter (Murakami Color Research Laboratory Co., Ltd., trade name “HM-150”). The permeable film was set alone and measured.

[Example 1]
The coating liquid 1 was applied (coated) to one surface of the base material (light-transmitting base material (A)) of Production Example 1 to form a coating layer (coating layer). Then, the said coating layer was heated at 90 degreeC for 1 minute, and was dried, and the coating film was formed. Then, the coating film was irradiated with ultraviolet rays having an integrated light amount of 300 mJ/cm ² by a high pressure mercury lamp to be cured to form an antiglare layer (B), thereby obtaining a target antiglare film. The maximum height Ry value of the antiglare layer (B) was 4.6 μm. In addition, in this example, the antiglare layer (B) is an antiglare hard coat layer. The same applies to each of the following Examples and Comparative Examples.

[Example 2]
An antiglare film was obtained in the same manner as in Example 1 except that the maximum height Ry value of the antiglare layer (B) was changed to 2.6 μm by changing the thickness of the coating film.

[Example 3]
An antiglare film was obtained in the same manner as in Example 1 except that the maximum height Ry value of the antiglare layer (B) was changed to 1.8 μm by changing the thickness of the coating film.

[Example 4]
An antiglare film was obtained in the same manner as in Example 1 except that the maximum height Ry value of the antiglare layer (B) was changed to 1.1 μm by changing the thickness of the coating film.

[Example 5]
An antiglare film was obtained in the same manner as in Example 1 except that the coating liquid 1 was changed to the coating liquid 2 and the maximum height Ry value of the antiglare layer (B) was set to 2.4 μm.

[Example 6]
An antiglare film was obtained in the same manner as in Example 5 except that the maximum height Ry value of the antiglare layer (B) was changed to 1.5 μm by changing the thickness of the coating film.

[Example 7]
An antiglare film was obtained in the same manner as in Example 5 except that the maximum height Ry value of the antiglare layer (B) was changed to 1.1 μm by changing the thickness of the coating film.

[Example 8]
An antiglare film was obtained in the same manner as in Example 1 except that the coating liquid 1 was changed to the coating liquid 3 and the maximum height Ry value of the antiglare layer (B) was set to 6.9 μm.

[Example 9]
An antiglare film was obtained in the same manner as in Example 1 except that the coating liquid 1 was changed to the coating liquid 3 and the maximum height Ry value of the antiglare layer (B) was 4.5 μm.

[Example 10]
An antiglare film was obtained in the same manner as in Example 1 except that the coating liquid 1 was changed to the coating liquid 3 and the maximum height Ry value of the antiglare layer (B) was set to 2.6 μm.

[Example 11]
An antiglare film was obtained in the same manner as in Example 5 except that the maximum height Ry value of the antiglare layer (B) was changed to 1.8 μm by changing the thickness of the coating film.

[Example 12]
An antiglare film was obtained in the same manner as in Example 5 except that the maximum height Ry value of the antiglare layer (B) was changed to 1.2 μ by changing the thickness of the coating film.

[Comparative Example 1]
On the antiglare layer (A) in the antiglare film of Example 2, fine particles of the cross-linked acrylic styrene copolymer resin from the coating liquid 1 (manufactured by Sekisui Plastics Co., Ltd., trade name: SSX1055QXE, average particle diameter: 5.5 μm) ) The coating liquid from which 8 parts had been removed was overcoated again. Thereafter, the overcoated layer was dried and cured in the same manner as in Example 1 to form an antiglare layer. The maximum height Ry value of this antiglare layer was less than 1.0 μm.

[Comparative example 2]
On the antiglare layer (A) in the antiglare film of Example 5, fine particles of the cross-linked acrylic styrene copolymer resin from the coating liquid 1 (manufactured by Sekisui Plastics Co., Ltd., trade name: SSX1055QXE, average particle diameter: 5.5 μm) ) The coating liquid from which 8 parts had been removed was overcoated again. Thereafter, the overcoated layer was dried and cured in the same manner as in Example 1 to form an antiglare layer. The maximum height Ry value of this antiglare layer was less than 1.0 μm.

[Comparative Example 3]
On the antiglare layer (A) in the antiglare film of Example 10, fine particles of the cross-linked acrylic styrene copolymer resin from the coating liquid 1 (manufactured by Sekisui Plastics Co., Ltd., trade name: SSX1055QXE, average particle diameter: 5.5 μm) ) The coating liquid from which 8 parts had been removed was overcoated again. Thereafter, the overcoated layer was dried and cured in the same manner as in Example 1 to form an antiglare layer. The maximum height Ry value of this antiglare layer was less than 1.0 μm.

[Comparative Example 4]
An antiglare film was obtained in the same manner as in Example 8 except that Smecton SAN was not added (addition amount 0 part) and the addition amount of fine particles was changed to 0.3 part. The average inclination angle θa of the irregularities of the antiglare layer in this antiglare film was less than 0.7 degrees.

[Comparative Example 5]
An antiglare film was obtained in the same manner as in Example 1 except that Smecton SAN was not added (addition amount 0 part) and the addition amount of fine particles was changed to 0.1 part. The average inclination angle θa of the irregularities of the antiglare layer in this antiglare film was less than 0.7 degrees.

The film thickness t in each of Examples 1 to 12 and Comparative Examples 1 to 5 (the maximum thickness of the antiglare layer (B) minus the maximum height of the convex and concave portions), the maximum of the convex and concave portions on the outermost surface Table 1 below shows the height Ry, the average inclination angle θa of the irregularities on the outermost surface, the haze value, and the reflection test result.

As shown in Table 1, in Examples 1 to 12 in which Ry and θa satisfy the requirements of the present invention, glare was suppressed. In contrast, in Comparative Examples 1 to 3 in which Ry and θa were out of the range of the present invention, the reflection was remarkable. Further, in Comparative Examples 4 and 5 in which Ry satisfied the requirements of the present invention, but θa was outside the range of the present invention, the reflection was remarkable.

As described above, according to the present invention, it is possible to provide an antiglare film, an optical member and an image display device in which glare is suppressed. According to the antiglare film of the present invention, for example, strong external light can be scattered and reflection can be suppressed, so that glare can be suppressed even outdoors. Therefore, the present invention can be suitably used for an image display device such as an outdoor public information display. However, the present invention is not limited to this application and can be used for a wide range of applications.

10 Anti-glare film 11 Light-transmissive substrate (A)
12 Antiglare layer (B)
12a Resin layer 12b Particles 12c Thixotropic agent 13 Other layer Ry Maximum height of convex portions of irregularities on the outermost surface d Maximum thickness D other than the light transmissive substrate (A) D Particle diameter Ry′ Antiglare layer (B ) Maximum height of convex portion of unevenness d′ Maximum thickness t of antiglare layer (B) Thickness of antiglare layer (B) (d′−Ry′)

Claims (13)

An antiglare film having an antiglare layer (B) laminated on a light transmissive substrate (A),
Unevenness is formed on the outermost surface of the antiglare film on the antiglare layer (B) side,
The anti-glare film, wherein the irregularities satisfy the following mathematical formulas (1) and (2).

Ry≧1 (1)
θa≧0.7 (2)

In the formula (1), Ry is the maximum height [μm] of the convex portion of the unevenness,
In the equation (2), θa is the average inclination angle [°] of the irregularities. The antiglare film according to claim 1, wherein the antiglare layer (B) contains fine particles. Unevenness is formed on the surface of the antiglare layer (B) opposite to the light transmissive substrate (A),
The antiglare film according to claim 2, wherein the weight average particle diameter of the fine particles is larger than the thickness obtained by subtracting the maximum height of the convex portions of the unevenness from the maximum thickness of the antiglare layer (B). The antiglare film according to claim 2 or 3, wherein the weight average particle diameter of the fine particles is in the range of 2 to 10 µm. The antiglare according to any one of claims 1 to 4, wherein another layer is further laminated on a surface of the antiglare layer (B) opposite to the light transmissive substrate (A). Sex film. An antiglare film in which an antiglare layer (B) and other layers are laminated on the light transmissive substrate (A) in the above order,
Unevenness is formed on the outermost surface of the other layer,
The anti-glare film, wherein the irregularities satisfy the following mathematical formulas (1) and (2).

Ry≧1 (1)
θa≧0.7 (2)

In the formula (1), Ry is the maximum height [μm] of the convex portion of the unevenness,
In the equation (2), θa is the average inclination angle [°] of the irregularities. An antiglare layer (B) forming step of forming the antiglare layer (B) on the light transmissive substrate (A) so as to satisfy the mathematical formulas (1) and (2);
In the antiglare layer (B) forming step, a coating step of applying a coating solution onto the light transmissive base material (A) and drying the applied coating solution to form a coating film. Including a coating film forming step,
The method for producing an antiglare film according to claim 1, wherein the coating liquid contains a resin and a solvent. The manufacturing method according to claim 7, wherein the antiglare layer (B) forming step further includes a curing step of curing the coating film. The manufacturing method according to claim 7, wherein the coating liquid contains fine particles. An optical member comprising the antiglare film according to claim 1. The optical member according to claim 10, which is a polarizing plate. An image display device comprising the antiglare film according to any one of claims 1 to 6 or the optical member according to claim 10 or 11. The image display device according to claim 12, which is a public information display.

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