JP4799986B2 - Transfer material for antireflection processing excellent in foil burr reduction and manufacturing method of transparent panel with antireflection film using the same - Google Patents

Description

  The present invention relates to an antireflection-processing transfer material excellent in foil burr reduction and a method for producing a transparent panel with an antireflection film using the same. Here, the transparent panel with an antireflection film is a mobile phone, a video camera, a digital camera, an automobile device, a PDA (Personal Digital Assistant), a monitor for a personal computer, a light, thin and flexible display electronic device such as paper. In various displays such as electronic paper, televisions, outdoor bulletin electronic devices, and the like, the display screen is transparently covered. Further, the transparent panel with an antireflection film is used in a transparent manner in a cover such as a frame, a photo stand, a clock, a window glass, and the like in addition to the various displays described above.

  Conventionally, in mobile phones, video cameras, digital cameras, automobile equipment, etc., liquid crystal panels and organic EL panels have been used for the display part. Usually, transparent panels are used to prevent damage to the display. The front surface of the display screen or the like is covered with a cover component constituted by Some of these cover parts are composed of a transparent panel molded into a convex lens shape to enlarge the display, and others are composed of a transparent panel on which a pattern such as a border is formed to decorate the vicinity of the screen.

  In the cover part, in order to make the displayed screen easy to see, it is required to form an antireflection film on the transparent panel. As one of the methods for forming an antireflection film on a transparent panel, a thermal transfer method using a transfer material for antireflection processing in which a transfer layer including an antireflection layer is directly or via a release layer on a substrate sheet Alternatively, a molding simultaneous transfer method is disclosed in Patent Document 1.

In the thermal transfer method, a transfer material is superimposed on a molded product, and a transfer layer in a required area is adhered to the molded product by heating and pressing with a transfer roll or the like from the substrate sheet side, and then the substrate sheet is peeled off to be transferred. In this method, only the transfer layer in the region is transferred to the object surface. In addition, the molding simultaneous transfer method is a method in which a transfer material is sandwiched in a molding die, molten resin is injected and filled into the cavity from the transfer layer side to obtain a resin molded product, and at the same time, the transfer material is adhered to the surface, In this method, after cooling and solidifying, the base sheet is peeled off and the transfer layer in the necessary region is transferred to the molded product.
JP 2002-221603 A

  In the thermal transfer method and the simultaneous molding transfer method described above, when the non-transfer portion of the transfer layer 111 provided larger than the transfer area of the transparent panel 1 that is a molded product, particularly when the transparent panel 1 has a shape having the hole 1a, a hole is formed. In a non-transfer portion of the transfer layer provided so as to cover 1a, after the substrate sheet is peeled off, a so-called foil that becomes thin and irregular protrusions with the transfer layer 111 attached to the periphery of the transparent panel 1 or the hole 1a Burr 5 is likely to occur (see FIG. 6). The foil burr 5 generated in the transparent panel 108 with the antireflection film is removed in a later step. For example, foil burrs are adhered to the adhesive tape manually and removed one by one on the ground.

  However, unlike the transfer portion, the non-transfer portion of the transfer layer 111 is not integrated with the surface of the transparent panel 1 and is fragile, and is formed by pressing with a transfer roll or the like in the thermal transfer method or molding at the time of mold clamping in the simultaneous molding transfer method. There is a problem that it is easily broken due to an impact due to a hit with a mold. As a result, the film forming the foil burr 5 may be separated from the transparent panel 108 with the antireflection film and fallen off before the foil burr 5 is removed.

  This drop-off piece becomes dust immediately after the drop-off or for a while, and floats in the air, and adheres to the roll forming surface of the transfer machine or the cavity forming surface of the molding die by the action of static electricity. In this case, the transfer after the next cycle is performed in a state in which the falling pieces are mixed as foreign matter between the base sheet and the roll or molding die of the transfer machine. As a result, traces of drop-off pieces appear as dents on the surface of the transparent panel 8 with the antireflection film, and there is a risk that the aesthetics will be significantly impaired.

  As a measure against dents, install an ion blower, static eliminator, suction device, etc. around the transfer machine and molding die to prevent falling pieces from adhering to the roll forming surface of the transfer machine and the cavity forming surface of the molding die. However, in that case, the installation cost and maintenance of these devices are expensive.

  Accordingly, the present invention provides a transfer material for antireflection processing which is excellent in so-called foil burr reduction property and a method for producing a transparent panel with an antireflection film using the same, which eliminates the above-mentioned drawbacks and hardly generates foil burrs. The purpose is to provide.

In order to achieve the above object, the present invention provides an antireflection film, wherein a transfer layer including an antireflection layer is formed on a substrate sheet so that the total thickness of the transfer layer is 0.15 to 0.8 μm. A method for producing an antireflection-processing transfer material for producing a transparent panel, wherein the cell volume is 2 to 2 when the antireflection layer is formed or an adhesive layer is formed on the antireflection layer. It is formed by gravure printing using a 5.5 cm ³ / m ² plate, and the gravure printing plate has a quadrangular pyramid shape with a cell number of 250 to 600 lines and a plate depth of 5 to 20 μm. configured in a certain way.

  Since this invention consists of an above-described structure, it has the following effects.

  That is, the transfer material for antireflection processing of the present invention has a total transfer layer thickness of 0.15 to 0.8 μm, which is very thin as compared with the conventional 3 to 20 μm. When obtaining a transparent panel with an antireflection film by thermal transfer method or simultaneous molding transfer method, foil burrs adhere to the periphery and holes of the transparent panel, or foil burrs fall off as dust and adhere to the transparent panel surface. As a result, defects are rarely generated. That is, the foil burr reduction property is excellent, and a transparent panel with an antireflection film can be obtained efficiently.

  Embodiments of the present invention will be described in detail with reference to the drawings.

  1 and 2 are cross-sectional views showing an embodiment of a transfer material for antireflection processing. 3 and 4 are cross-sectional views showing an embodiment of a method for producing a transparent panel with an antireflection film. FIG. 5 is a sectional view showing an embodiment of the transparent panel with an antireflection film of the present invention. In the figure, 1 is a transparent panel, 1a is a hole, 2 is an adhesive layer, 3 is a release layer, 4 is an antireflection layer, 6 is a transfer material for antireflection processing, 7 is a base sheet, and 8 is transparent with an antireflection film. A panel, 9 is a molding die, 10 is a molten resin, 11 is a transfer layer, and 12 is a heat-resistant rubber-like elastic body.

  First, the anti-reflection transfer material 6 having excellent foil burr reduction properties of the present invention will be described.

  The transfer material 6 for antireflection processing is obtained by forming a transfer layer 11 including an antireflection layer 4 on a base sheet 7, and after the transfer layer of a necessary region is adhered to the surface of the transparent panel, the base sheet 7. Is peeled off, and the transfer layer 11 is formed on the surface of the transparent panel (see FIGS. 1 and 2).

  As a material of the base sheet 7, a resin sheet such as a polypropylene resin, a polyethylene resin, a polyamide resin, a polyester resin, an acrylic resin, or a polyvinyl chloride resin can be used.

  When the peelability of the antireflection layer 4 from the base sheet 7 is good, the transfer layer 11 including the antireflection layer 4 can be directly provided on the base sheet 7 (see FIG. 1). In order to improve the peelability of the transfer layer 11 from the base sheet 7, the release layer 3 may be formed on the entire surface before the transfer layer 11 is provided on the base sheet 7 (see FIG. 2).

  The material of the antireflection layer 4 includes a vapor deposition layer of a metal compound such as Al ↓ 2O ↓ 3, ZnO2 and MgF ↓ 2, a metal compound having a low refractive index such as SiO ↓ 2 and MgF ↓ 2, and ZnO ↓ 2 and TiO2. A vapor deposition layer obtained by laminating a metal compound having a high refractive index such as ↓ 2 or a resin coating layer made of a fluorine-based polymer or silicon oxide gel can be used. A combination of these may also be used.

  Examples of the method for forming the antireflection layer 4 include a vacuum deposition method, a sputtering method, and an ion plating method. Alternatively, an organic metal compound such as a metal alcoholate or metal chelate is applied onto the substrate sheet 7 by a printing method such as an immersion method or gravure printing or a coating method, and then a metal oxide film is formed by light irradiation or drying. There is also a method for obtaining the antireflection layer 4.

  The film thickness of the antireflection layer 4 is the general formula n × d = λ / 4 or the general formula n × d = 3λ / 4 (where n is the refractive index of the low refractive index material and d is the thickness of the low refractive index material) , Λ may be selected as appropriate so as to satisfy the low reflection center wavelength. When the antireflection layer 4 is formed with such a thickness, the reflected light from the surface of the antireflection layer 4 and the reflected light from the opposite surface cancel each other out due to interference, and the reflectance is reduced, so that the best antireflection effect is achieved. Is demonstrated. For example, in the case of the antireflection layer 4 having a refractive index of 1.36, when the center wavelength of transmitted light is 550 nm, the thickness of the antireflection layer 4 is optimally about 0.1 μm.

  The antireflection layer 4 may be a single low refractive index layer or a composite layer such as a low refractive index layer and a high refractive index layer. When a composite layer is used, the antireflection property can be further improved. In order to eliminate the increase in the number of steps when the composite layer is formed, it is very efficient to form the antireflection layer 4 by a roll-to-roll continuous coating method. Here, the low refractive index and the high refractive index refer to a comparison result with the refractive index of a layer located below these layers. For example, when the antireflection layer 5 has a single-layer structure, the refractive index of the adhesive layer 2 described later (the transparent panel 1 when there is no adhesive layer 2) is a comparison target. Further, when the antireflection layer 4 is a composite layer, the refractive indexes of the layers located immediately below each layer constituting the antireflection layer 4 are to be compared.

  In addition, you may provide an antifouling layer as a layer which becomes the outermost surface by peeling of the base material sheet 7 among the transfer layers 11 as needed. As a material for the antifouling layer, a surfactant having fluorine at the terminal group may be used. In order to provide the antifouling layer, a coating method, a dipping method, a vacuum deposition method or the like may be used.

  Moreover, it is good to form the contact bonding layer 2 for adhere | attaching these layers and the transparent panel 8 on the antireflection layer 4 (refer FIG. 2). As the adhesive layer 2, a heat-sensitive or pressure-sensitive resin suitable for a transparent panel material is appropriately used.

  For example, when the material of the transparent panel 1 is an acrylic resin, an acrylic resin may be used. When the material of the transparent panel 1 is polyphenylene oxide / polystyrene resin, polycarbonate resin, or polystyrene blend resin, acrylic resin, polystyrene resin, polyamide resin, or the like having an affinity for these resins should be used. That's fine. Furthermore, when the material of the transparent panel 1 is a polypropylene resin, chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin can be used. As a method for forming the adhesive layer 2, there are a gravure printing method, a coating method such as a roll coating method and a comma coating method, and a printing method such as an offset printing method in addition to a gravure printing method.

  However, in order to obtain the foil burr reduction effect as in the present invention, it is important to make the total thickness of the transfer layer 11 including the antireflection layer 4 thinner than 0.8 μm. When the film thickness is greater than 0.8 μm, the number of foil burrs increases rapidly (specifically, the rate of occurrence of foil burrs exceeds 10%), and the features of the present invention cannot be obtained. In order to make almost no foil burrs (specifically, the rate of occurrence of foil burrs is 3% or less), the total thickness of the transfer layer 11 including the antireflection layer 4 is less than 0.4 μm. It is recommended to make it thinner (see the table below). Further, considering the minimum thickness of the antireflection layer 4 necessary for exhibiting the antireflection effect and the presence of the transfer layer 11 other than the antireflection layer 4, the lower limit of the total thickness of the transfer layer 11 in the present invention is 0. .15 μm or more.

When performing gravure printing on the antireflection layer 4 or the adhesive layer 2 in the present invention, a plate having a cell volume of ² to 5.5 cm ³ / m ² is used to reduce the thickness of the formed layer. preferable. Specifically, if the shape of the cell is a quadrangular pyramid, the number of lines is 250 to 600 lines, and the plate depth is 5 to 20 μm, the plate with the above cell volume can be obtained (see Table 2 below).

  For example, if the ink of the adhesive layer 2 is printed with an appropriate viscosity for normal gravure printing using the plate having the cell volume described above, the adhesive layer 2 having a thickness of 0.1 to 0.4 μm is formed.

  The configuration of the transfer layer 11 is not limited to the above-described aspect. For example, when using a material having excellent adhesion to the transparent panel as the material of the antireflection layer 4, the adhesive layer 2 may be omitted.

  A transparent panel with an antireflection film can be easily obtained using the transfer material 6 for antireflection processing having the above-described configuration and excellent anti-foil burr reduction property, using a thermal transfer method or a simultaneous molding transfer method.

  Next, a method for manufacturing the transparent panel 8 with an antireflection film using the transfer material 6 described above by a thermal transfer method will be described (see FIG. 3).

  First, the transparent panel 1 is placed in a transfer machine such as a roll transfer machine or an up-down transfer machine provided with a heat-resistant rubber-like elastic body (transfer roll or transfer pad) 12 such as silicon rubber on the surface of the transparent panel 1. The transfer material 6 for antireflection processing is fed in and the transfer layer 11 side is brought into close contact with the surface of the transparent panel 1. At that time, a single sheet of transfer material may be fed one by one, or a necessary part of a long transfer material may be intermittently fed.

  Next, heat and pressure are applied from the base sheet 7 side of the antireflection transfer material 6 through the heat-resistant rubber-like elastic body 12. By doing so, the transfer layer 11 adheres to the surface of the transparent panel 1.

  When the substrate sheet 7 is peeled off after cooling, peeling occurs at the boundary surface between the substrate sheet 7 and the transfer layer 11, and the transfer is completed. When the release layer 3 is provided on the base sheet 7, when the base sheet 7 is peeled off, peeling occurs at the boundary surface between the release layer 3 and the transfer layer 11, and the transfer is completed. Thus, the transparent panel 8 with an antireflection film can be obtained.

  In addition, a method for manufacturing the transparent panel 8 with the antireflection film using the transfer material 6 described above by the simultaneous molding transfer method will be described (see FIG. 4).

  First, the anti-reflection transfer material 6 is fed into the molding die 9. At that time, a single sheet of transfer material may be fed one by one, or a necessary part of a long transfer material may be intermittently fed.

  After the molding die 9 is closed, molten resin 10 is injected and filled into the cavity 13 from the gate, and at the same time as the transparent panel 1 is molded, the antireflection transfer material 6 is adhered to the surface thereof.

  After cooling and solidification, the molding die 9 is opened to take out an integrated product of the antireflection processing transfer material 6 and the transparent panel 1, and the base sheet 7 is peeled off, whereby the boundary between the base sheet 7 or the release layer 3 and the transfer layer 11. Peeling occurs on the surface, and simultaneous molding transfer is completed. Thus, the transparent panel 8 with an antireflection film can be obtained.

  The transparent panel 1 may have a flat plate shape as a whole or a two-dimensional or three-dimensional curved surface.

  Examples of the material that can be used for the transparent panel 1 include general-purpose resins such as polystyrene resin, polyolefin resin, ABS resin, AS resin, and AN resin. Also, general engineering resins such as polyphenylene oxide / polystyrene resins, polycarbonate resins, polyacetal resins, acrylic resins, polycarbonate-modified polyphenylene ether resins, polybutylene terephthalate resins, ultrahigh molecular weight polyethylene resins, polysulfone resins, polyphenylene sulfide Super engineering resins such as resins, polyphenylene oxide resins, polyarylate resins, polyetherimide resins, polyimide resins, liquid crystal polyester resins, and polyallyl heat-resistant resins can also be used. Moreover, you may mix the light-diffusion agent etc. which consist of silica beads, acrylic beads, etc. in these molding resin. Further, when the transparent panel 8 with the antireflection film is obtained by the thermal transfer method, glass can be used as the material of the transparent panel 1.

A cell sheet having an antireflection layer made of a urethane acrylate resin having a thickness of 0.12 μm and an adhesive layer made of an acrylic resin having a thickness of 0.18 μm on the polyester sheet having a thickness of 38 μm. It was formed using a gravure plate of 9 cm ³ / m ² (cell shape: quadrangular pyramid type, number of lines: 400 lines, plate depth: 10 μm), and transfer material 6 for antireflection processing was obtained.

  Next, the antireflection processing transfer material is sandwiched in a molding die, and a transparent panel is obtained by injection-filling a transparent molten resin made of acrylic resin into the cavity from the transfer layer side, and at the same time, a necessary area on the surface thereof. The transfer layer was adhered, and after cooling and solidifying, the base sheet was peeled off to obtain a transparent panel with an antireflection film in which a transfer layer including an antireflection layer was formed on the surface of the transparent panel.

  The occurrence rate of the foil burrs of the transparent panel with the antireflection film thus obtained and the failure occurrence rate due to the dust adhesion of the foil burrs were measured for 2000 pieces, and the occurrence rate of the foil burrs was 1.3%. Defect occurrence rate due to dust adhesion is 1.6%, lower than conventional foil burr occurrence rate (usually about 30%) and defect occurrence rate due to dust adhesion of foil burr (usually around 10%), and excellent productivity It was.

A cell sheet having an antireflection layer made of a urethane acrylate resin having a thickness of 0.10 μm and an adhesive layer made of an acrylic resin having a thickness of 0.13 μm on the polyester sheet having a thickness of 25 μm. It was formed using a gravure plate of 6 cm ³ / m ² (cell shape; quadrangular pyramid type, number of lines: 500 lines, plate depth: 10 μm), and transfer material 6 for antireflection processing was obtained.

  Next, an acrylic plate (transparent panel) and the antireflection processing transfer material are placed on the transfer machine, the acrylic plate and the antireflection processing transfer material are pressed with a hot roll, and the substrate sheet is peeled off after cooling. Thus, a transparent panel with an antireflection film in which a transfer layer including an antireflection layer was formed on the transparent panel surface was obtained.

  When the occurrence rate of foil burrs in the transparent panel with the antireflection film thus obtained and the defect occurrence rate due to dust adhesion of the foil burrs were measured for 2000 pieces, the occurrence rate of foil burrs was 1.2%, Defect occurrence rate due to dust adhesion is 1.5%, lower than conventional foil burr occurrence rate (usually about 30%) and defect occurrence rate due to dust adhesion of foil burr (usually around 10%), and excellent productivity It was.

It is sectional drawing which shows one Example of the transfer material for antireflection processing. It is sectional drawing which shows one Example of the transfer material for antireflection processing. It is sectional drawing which shows one Example of the manufacturing method of the transparent panel with an antireflection film. It is sectional drawing which shows one Example of the manufacturing method of the transparent panel with an antireflection film. It is sectional drawing which shows one Example of the transparent panel with an antireflection film concerning this invention. It is sectional drawing which shows one Example of the transparent panel with an antireflection film concerning a prior art.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transparent panel 1a Hole 2 Adhesive layer 3 Release layer 4 Antireflection layer 5 Foil burr 6 Transfer material for antireflection processing 7 Base sheet 8 Transparent panel with antireflection film 9 Molding die 10 Molten resin 11 Transfer layer 12 Heat resistant rubber Elastic body 108 Transparent panel with antireflection film 111 Transfer layer

Claims (1)

Transfer for antireflection processing for producing a transparent panel with an antireflection film in which a transfer layer including an antireflection layer is formed on a base sheet so that the total thickness of the transfer layer is 0.15 to 0.8 μm A method for producing a material, wherein the cell volume is 2 to 5.5 cm when the antireflection layer is formed or an adhesive layer is formed on the antireflection layer. ³ / M ² And the gravure printing plate has a quadrangular pyramidal shape, 250 to 600 lines, and a plate depth of 5 to 20 μm. A method for producing a transfer material for prevention processing.

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