JP5398521B2 - Matte sheet manufacturing method - Google Patents

Description

  The present invention relates to a method for producing a matte sheet.

  In an image display device such as a liquid crystal display device, a method of forming a member having a concavo-convex shape on the surface of an image display device is known in order to suppress a decrease in visibility due to reflection of external light.

  As a method for forming a concavo-convex shape on the surface of a member, for example, in Patent Document 1, a matte film having a concavo-convex shape on the surface is prepared and applied to a coating film of an ionizing radiation curable resin composition formed on a resin substrate. Lamination so that the uneven surfaces of the mat film are combined, the coating film of the ionizing radiation curable resin composition is cured, and the mat film is peeled off from the cured coating film of the ionizing radiation curable resin composition. A method of manufacturing a resin base material having an uneven shape has been proposed.

  However, in this method, since the peelability between the mat film and the ionizing radiation curable resin composition is not good, the mat film does not peel off, and a matte sheet having an uneven shape may not be obtained.

  In addition, depending on the shape of the concavo-convex shape formed on the surface of the member, when arranged on the surface of the image display device, there is a problem that a so-called “whiteness” phenomenon occurs in which the entire display surface becomes whitish due to scattered light. .

  Furthermore, when it is arranged on the surface of a high-definition image display device, there is a problem that “glaring” that is luminance unevenness of an image generated by interference between the pixel and the uneven surface of the member on which the uneven shape is formed occurs. .

  In order to overcome these problems, it is necessary to form an optimal concavo-convex shape, but in order to realize the optimal concavo-convex shape, it is necessary to consider the width, depth, inclination angle, etc. of the concavo-convex. Conventionally, “glare” tends to be emphasized when trying to suppress “white flare”, and “white flare” tends to be emphasized when trying to suppress “glare”. Development of a method for producing a matte sheet having a specific concavo-convex shape capable of simultaneously suppressing “stickiness” is desired.

  As a method for producing a mat sheet having a specific concavo-convex shape, for example, in Patent Document 2, a surface and a substrate on which a concavo-convex shape of a shaping film adjusted to a desired concavo-convex shape is formed by applying a resin to the surface. There has been proposed a method of obtaining a matte sheet by laminating an ionizing radiation curable resin layer formed on a film, then curing the ionizing radiation curable resin layer, and further peeling the shaped film.

  However, when the laminate having a concavo-convex shape on the surface obtained in Patent Document 2 is applied to a liquid crystal display, it cannot be said that the problem of “glare” is solved. Also, when peeling the shaping film from the cured layer of the coating film of the ionizing radiation curable resin composition, the matting sheet having the desired concavo-convex shape may not be obtained due to insufficient peelability of the shaping film. There is a problem that there is.

  Patent Document 3 discloses that a peelable film and a UV curable resin layer formed on a base film are overlapped with each other and cured after being overlapped with the UV curable resin layer. A method for forming an epoxy melamine resin layer on the surface of a shaped film for the purpose of imparting the above is described. However, in this method, the peelability between the shaping film and the ultraviolet curable resin layer is not sufficient, and it is difficult to obtain a desired matte sheet.

  Further, Patent Document 4 discloses light pollution such as that the unevenness is formed on the outer surface of the surface protection member of the solar cell module and the reflected light is scattered so that the reflected light illuminates a neighboring house or building. It is stated that this problem will be solved. However, in this invention, since a glass plate is used for the surface protection member, the solar cell module becomes heavy, and there is a problem that a construction for reinforcing the structure of the house is required when installing on the roof.

Japanese Patent Application Laid-Open No. 64-51174 International Publication No. 95/31737 Pamphlet Japanese Patent Laid-Open No. 2004-77781 JP 2001-57439 A

  An object of the present invention is to provide a method for producing a matte sheet having a specific concavo-convex shape which is excellent in antiglare property and suppressed glare and whitishness.

The gist of the present invention is a method for producing a matte sheet having the following steps (1) to (7), and an active energy ray-curable composition having an uneven shape on at least one surface of a sheet-like substrate. It exists in the manufacturing method of the matte sheet | seat with which the hardened material layer was laminated | stacked.
(1) A mat film surface treatment step for subjecting the surface of the mat film having an uneven shape to at least one surface to a discharge gas. (2) For coating containing a melamine-based resin composition on the surface of the surface-treated mat film. A coating solution coating layer forming step of coating the solution to form a coating solution coating layer on the surface of the mat film (3) The mat is cured by curing the melamine resin composition in the coating solution coating layer. A laminated film forming step for forming a laminated film having a concavo-convex shape in which a melamine-based resin cured layer is laminated on the surface of the film (4) An active energy ray-curable composition is applied to at least one surface of a sheet-like substrate Active energy ray-curable composition coating layer forming step for forming an active energy ray-curable composition coating layer on the surface of the sheet-like substrate (5) Active energy ray hardness of the sheet-like substrate A laminate of a laminated film and a sheet-like substrate having an active energy ray-curable composition-coated layer is bonded to the surface of the laminated film on which the melamine-based resin cured layer is formed. Laminate formation step to be formed (6) Active energy ray curable composition coating layer from at least one of upper surface or lower surface of laminate of sheet-like base material and laminated film having active energy ray curable composition coating layer Active energy ray curable composition coating layer is cured by irradiating active energy ray to form active energy ray curable composition cured layer-containing laminate having active energy ray curable composition cured layer Line curable composition cured layer-containing laminate formation step (7) surface by peeling the laminated film from the active energy ray curable composition cured layer-containing laminate Matte sheet forming step of the active energy ray-curable composition cured layer having irregularities forming a matte sheet laminated

  The pitch between irregularities (Sm), surface roughness (Ra), maximum height roughness (Rz), and average inclination of surface irregularities (Δa), which can be obtained by the method of the present invention, were set in the optimum ranges, A matte sheet having a specific concavo-convex shape is excellent in antiglare properties, has suppressed glare and whitishness, and can be suitably used as a front plate of an image display device. Furthermore, since the reflection of sunlight is scattered, it can be suitably used as a surface protection member of a solar cell module.

It is sectional drawing which shows an example of the laminated | multilayer film used by this invention. It is a schematic block diagram which shows an example of the manufacturing apparatus of the sheet-like base material used by this invention.

Matte Film The matte film used in the present invention has an uneven shape on at least one surface of the film. The uneven shape is preferably an uneven pitch (Sm) of 1 to 50 μm, a surface roughness (Ra) of 100 to 400 nm, and an average slope (Δa) of 2 to 10 ° of surface unevenness.

・・・式（１）
表面粗さ（Ｒａ）
ここでＲａとは、粗さ曲線から基準線までの距離の絶対値の算術平均偏差をいい、式（２）で現される。
Ｒａ＝（ｙ１＋ｙ２＋ｙ３＋・・・ｙｎ）／ｎ ・・・式（２）
ｙｎは各点の座標の絶対値で、ｎは離散要素数を表す。
最大高さ粗さ（Ｒｚ）
ここでＲｚとは、基準線に平行な線により測定された評価長さ内の、５つの最も高い山と５つの最も低い谷の平均距離をいい、式（３）で表される。
Ｒｚ＝{（Ｐ１＋Ｐ２＋Ｐ３＋Ｐ４＋Ｐ５）−（Ｖ１＋Ｖ２＋Ｖ３＋Ｖ４＋Ｖ５）}／５
・・・・・・・・式（３）
Ｐｎは山の高さの絶対値、Ｖｎは谷の深さの絶対値を表す。
表面凹凸の平均傾斜（△ａ）
△ａは、粗さ曲線の平均傾斜角をいい、式（４）で表される。
ここでｘ、ｙはｘ−ｙ平面における座標であり、ｌは評価長さを示す。
＜式４＞

・・・・・・・・（式４）

これらＳｍ、Ｒａ、Ｒｚ、△ａの値は、例えばＺｙｇｏ社製の光干渉式表面形状測定器であるＮｅｗＶｉｅｗ６３００（商品名）にて測定したデータを、Ｚｙｇｏ社製のデータ解析用ソフトウェアであるＭｅｔｒｏＰｒｏ（商品名）によって解析して得られる。 In the present invention, the pitch between irregularities (Sm), the surface roughness (Ra), the maximum height roughness (Rz) and the average inclination (Δa) of the surface irregularities can be obtained by the following formulas.
Concavity and convexity pitch (Sm)
Here, Sm is the average value of the sum of the lengths of the reference lines corresponding to one peak and one valley adjacent to it, extracted from the roughness curve by the evaluation length in the direction of the reference line. It is represented by (1).
<Formula 1>

... Formula (1)
Surface roughness (Ra)
Here, Ra refers to the arithmetic mean deviation of the absolute value of the distance from the roughness curve to the reference line, and is expressed by Equation (2).
Ra = (y1 + y2 + y3 +... Yn) / n (2)
yn is the absolute value of the coordinates of each point, and n represents the number of discrete elements.
Maximum height roughness (Rz)
Here, Rz refers to the average distance between the five highest peaks and the five lowest valleys in the evaluation length measured by a line parallel to the reference line, and is represented by Expression (3).
Rz = {(P1 + P2 + P3 + P4 + P5)-(V1 + V2 + V3 + V4 + V5)} / 5
・ ・ ・ ・ ・ ・ ・ ・ Formula (3)
Pn represents the absolute value of the height of the mountain, and Vn represents the absolute value of the depth of the valley.
Average slope of surface irregularities (△ a)
Δa refers to the average inclination angle of the roughness curve, and is represented by Expression (4).
Here, x and y are coordinates in the xy plane, and l indicates the evaluation length.
<Formula 4>

... (Formula 4)

These values of Sm, Ra, Rz, and Δa are obtained by measuring the data measured by NewView 6300 (trade name), which is an optical interference type surface shape measuring instrument made by Zygo, for example, and MetroPro, which is data analysis software made by Zygo. Obtained by analysis according to (trade name).

  When the pitch (Sm) between the irregularities on the surface of the matte film is 1 μm or more, whitening of the matte sheet is suppressed, and when it is 50 μm or less, glare of the matte sheet tends to be suppressed.

  Moreover, when the surface roughness (Ra) of the surface of the matte film is 100 nm or more, the antiglare property is good, and when it is 400 nm or less, whitening tends to be suppressed.

  Furthermore, when the average slope (Δa) of the surface roughness of the matte film is 2 ° or more, the anti-glare sheet has good antiglare properties, and when it is 10 ° or less, the whitening of the mat sheet tends to be suppressed. .

  Examples of the matte film include polyester films such as polyethylene terephthalate films, polyolefin films such as polyethylene films and polypropylene films, polyvinyl chloride films, acetyl cellulose butyrate films, triacetyl cellulose films, polystyrene films, polycarbonate films, and polymethylpentene. Examples include films and polysulfone films. Among these, a polyethylene terephthalate film (hereinafter referred to as “PET film”) is preferable in terms of availability and cost.

  The method for producing the mat film is not particularly limited, a method for imparting an uneven shape to a film-like substrate by embossing, a method for imparting an uneven shape by kneading fine particles into a film-like substrate, and dry ice for a film-like substrate. And the like, a method of spraying the active energy ray-curable composition on the surface of the film-like substrate, and then pressing the mold having a concavo-convex shape to cure the curable composition layer and peeling the mold, etc. A method is mentioned.

  Active energy ray curable used in a method in which an active energy ray curable composition is applied to the surface of a film-like substrate and then a mold having an uneven shape is pressed to cure the curable composition layer and peel the template. What was described in the term of the active energy ray curable composition mentioned later can be used for a composition.

Matt Film Surface Treatment Step In the present invention, when the mat film is used, in the mat film surface treatment step, the surface of the mat film having a concavo-convex shape is subjected to a surface treatment by a treatment of exposing to a discharge gas.

  By performing a surface treatment (hydrophilization treatment) on the surface of the mat film having a concavo-convex shape, the adhesion between the mat film and the cured melamine resin layer described later is improved. The peelability from the active energy ray-curable composition cured layer obtained by curing the active energy ray-curable composition-coated layer becomes good.

  Examples of the hydrophilization treatment method include corona discharge, atmospheric pressure or low pressure glow discharge, exposure to a discharge gas such as atmospheric pressure or low pressure arc discharge, exposure to active energy rays in the presence of oxygen, exposure to ozone gas, A known method such as a method of immersing in an alkaline solution can be used. In the present invention, from the viewpoint of processing efficiency, a processing method exposed to a discharge gas is preferable, and among these, a processing method exposed to corona discharge, atmospheric pressure glow discharge, and atmospheric pressure arc discharge is preferable from the viewpoint of simplicity of the apparatus.

  The gas component constituting the discharge gas used for the surface treatment is not particularly limited as long as the gas can stably maintain the discharge, and examples thereof include air, nitrogen, oxygen, helium, neon, and argon.

  Among these, air, nitrogen, oxygen, helium and argon are preferable in terms of discharge stability and economy. These can be used alone or in combination of two or more.

  Although it does not specifically limit as time to expose the surface of a mat | matte film to discharge gas, 0.5 to 5 second is preferable. The time for which the surface of the mat film is exposed to the discharge gas is 0.5 seconds or more, and the peelability between the laminated film and the active energy ray-curable composition cured layer, which will be described later, tends to be good. There is a tendency that deformation of the matte film due to contact with is suppressed.

Coating Solution The coating solution used in the present invention contains a melamine resin composition and an organic solvent described later.

  The coating solution is for forming a cured melamine resin layer on at least one surface of the matte film having a concavo-convex shape.

  In the present invention, by adjusting the concentration of the melamine-based resin composition of the coating solution, the pitch between concave and convex shapes (Sm), surface roughness (Ra), and maximum height roughness formed on the surface of the laminated film. The thickness (Rz) and the average slope (Δa) of the surface irregularities can be set to a desired shape.

  As the concentration of the melamine-based resin composition in the coating solution, in terms of suppressing thickness unevenness of the cured melamine-based resin layer formed by curing the melamine-based resin composition on the surface having an uneven shape of the mat film, 0.01-90 mass% is preferable.

  In the present invention, a polymerizable monomer can be contained in the coating solution as necessary.

  Examples of the polymerizable monomer include a thermosetting resin monomer and an active energy ray curable resin monomer.

  Specific examples of the thermosetting resin monomer include phenol, formaldehyde, urea, ethylene glycol and terephthalic acid.

  Specific examples of the active energy ray-curable resin monomer include those similar to the polymerizable compound having at least two (meth) acryloyloxy groups in the molecule in the active energy ray-curable composition described later. It is done.

Melamine-based resin composition Examples of the melamine-based resin composition used in the present invention include a resin composition containing a melamine resin and at least one selected from an acrylic resin, an epoxy resin, and an alkyd resin. In the present invention, only a melamine resin may be used instead of the melamine resin composition, and in that case, it is also referred to as a melamine resin composition for convenience.

  Moreover, as content of the melamine resin in a melamine type resin composition, 70-99 mass% is preferable at the peelable point of a melamine type resin cured layer and the active energy ray-curable composition cured layer mentioned later.

  Examples of the melamine resin used in the present invention include melamine formaldehyde resin, methylated melamine formaldehyde resin, butylated melamine formaldehyde resin, etherified melamine formaldehyde resin, epoxy-modified melamine formaldehyde resin, urea melamine resin and acrylic melamine resin. It is done.

  Specific examples of the melamine resin include Melan 2000 (trade name) manufactured by Hitachi Chemical Co., Ltd. and MX730 (trade name) manufactured by Sanwa Chemical Co., Ltd. Each of these products is obtained by dissolving a melamine resin in an organic solvent.

  Melamine resins can be used alone or in combination of two or more.

  Commercially available acrylic resins for paints can be used as the acrylic resin. Specific examples thereof include Dainar HR656 and LR2666 manufactured by Mitsubishi Rayon Co., Ltd., ACRYDIC A-1815 manufactured by DIC Corporation, Nippon Paint Co., Ltd. ) Super rack 200T (both are trade names).

  A commercially available epoxy resin for paints can be used as the epoxy resin, and examples thereof include an epoxy polyol resin, and specific examples thereof include Epicron U-150 manufactured by DIC Corporation.

  Commercially available alkyd resins can be used as the alkyd resins, and examples thereof include vinyl-modified alkyd resins, epoxy-modified alkyd resins, and silicone-modified alkyd resins.

  Specific examples of the alkyd resin include phthalkid E4330-1 (trade name) manufactured by Hitachi Chemical Co., Ltd., Haliftal KV-905 (trade name) manufactured by Harima Chemical Co., Ltd., and Beccosol ER-3615 manufactured by DIC Corporation ( Product name).

  Various additives such as a mold release agent, a surfactant, a leveling agent, a stabilizer, and fine particles can be blended in the melamine resin composition according to the purpose.

  As a compounding quantity of the said additive, 0.05-10 mass parts is preferable with respect to 100 mass parts of melamine type-resin compositions.

  A curing accelerator can be added to the melamine resin composition used in the present invention as necessary.

  Examples of the curing accelerator include acidic phosphoric acid alkyl ester and dodecylbenzenesulfonic acid. Specific examples of the curing accelerator include P-198 manufactured by DIC Corporation.

  Although the addition amount of a hardening accelerator can be suitably selected in the range which does not impair the physical property of a melamine type resin hardened layer, 0.05-10 mass parts is preferable with respect to 100 mass parts of melamine type resin compositions.

Organic Solvent The organic solvent used in the present invention is for obtaining a coating solution for forming a cured melamine-based resin layer on the surface of the matte film having an uneven shape, and dissolves the melamine-based resin composition. It is a solvent.

  As the organic solvent, those having good solubility of the melamine-based resin composition, volatilizing in a short time in the drying step, and not polluting the environment are preferable.

  Examples of the organic solvent include toluene, acetone, methyl ethyl ketone, methanol, ethanol, propanol, and dimethylformamide. These can be used alone or in combination of two or more.

Coating Solution Coating Layer In the present invention, the coating solution coating layer is formed on at least one surface having an uneven shape of a mat film.

Coating solution coating layer forming step In the present invention, in the coating solution coating layer forming step, a coating solution coating layer is formed on the surface of the surface-treated mat film.

  Examples of the method for applying the coating solution to the surface of the mat film include a bar coater method, a dipping method, a spray coating method, a spin coating method, a roll coating method, a gravure coating method, and a flow coating method.

  In the present invention, by adjusting the concentration of the melamine-based resin composition in the coating solution and the thickness of the coating solution coating layer, the uneven pitch between the concaves and convexes (Sm) formed on the surface of the laminated film, the surface roughness The thickness (Ra), the maximum height roughness (Rz), and the average slope (Δa) of the surface irregularities can be made into desired shapes.

  For example, when the surface roughness of the concavo-convex shape of the mat film is significantly larger than the desired roughness of the concavo-convex shape of the laminated film, it is necessary to increase the thickness of the coating solution coating layer to be laminated on the mat film surface.

  The method for controlling the thickness of the coating solution coating layer varies depending on the coating method of the coating solution. For example, in the case of coating by the bar coater method, the number of the bar coater and the melamine resin composition of the coating solution It can be adjusted by the concentration.

Laminated film In the present invention, the laminated film is a film in which a melamine-based resin cured layer is laminated on the surface of the mat film having an uneven shape.

  FIG. 1 is a cross-sectional view showing an example of a laminated film. In the laminated film 11, a cured melamine resin layer 11b is laminated on the surface of a mat film 11a having an uneven shape.

  The surface of the laminated film has an uneven shape. The concavo-convex shape has a pitch between concavo-convex of 1 to 30 μm (Sm), a surface roughness (Ra) of 100 to 200 nm, a maximum height roughness (Rz) of 200 to 700 nm, and an average inclination of surface concavoconvex of 2 to 5 °. (Δa) is preferred.

  The whiteness of the matte sheet obtained when the pitch between irregularities (Sm) is 1 μm or more is suppressed, and the glare of the matte sheet tends to be suppressed when it is 30 μm or less.

  Further, when the surface roughness (Ra) is 100 nm or more, the antiglare property of the matte sheet is good, and when the surface roughness is 200 nm or less, whitening of the matte sheet tends to be suppressed.

  Furthermore, when the maximum height roughness (Rz) is 200 nm or more, the anti-glare property of the matte sheet is good, and when it is 700 nm or less, the whitening of the matte sheet tends to be suppressed.

  Further, when the average slope (Δa) of the surface irregularities is 2 ° or more, the antiglare property of the matte sheet is good, and when it is 5 ° or less, the whitening of the matte sheet tends to be suppressed.

  In the present invention, the thickness of the cured melamine resin layer laminated on the surface of the mat film is preferably 10 nm to 10 μm. When the thickness of the melamine-based resin cured layer is 10 nm or more, whitening of the matte sheet tends to be suppressed. Moreover, when the thickness of the cured melamine resin layer is 10 μm or less, the antiglare property of the matte sheet tends to be good.

Laminated film forming step In the present invention, the organic solvent in the coating solution coating layer formed on the surface of the matte film in the laminated film forming step is removed and the melamine resin composition is cured to form the matte film surface. To form a cured melamine resin layer.

  Examples of the method for removing the organic solvent include a room temperature drying method, a reduced pressure drying method, and a heat drying method. Among these, the heat drying method is preferable in that the process can be simplified by curing the melamine resin composition simultaneously with the removal of the organic solvent.

  The heating and drying temperature is preferably 50 to 150 ° C. The condensation reaction of the melamine resin proceeds sufficiently in a short time at a heating and drying temperature of 50 ° C. or higher, and the peelability between the laminated film and the active energy ray-curable composition cured layer tends to be good. Moreover, it exists in the tendency for the heat drying temperature to suppress the deformation | transformation by the heat | fever of a laminated film at 150 degrees C or less.

  The heat drying time is preferably 5 to 60 minutes. Curing by the condensation reaction of the melamine resin proceeds sufficiently when the heat drying time is 5 minutes or more, and the peelability between the laminated film and the active energy ray-curable composition cured layer tends to be good. Moreover, it is in the tendency for the deformation | transformation by the heat | fever of a laminated | multilayer film to be suppressed by heat drying time 60 minutes or less.

  In addition, when a polymerizable monomer is contained in the coating solution, the polymerizable monomer can be polymerized after removing the organic solvent in the coating solution coating layer.

Sheet-like base material Examples of the sheet-like base material used in the present invention include acrylic resins, polycarbonate resins, polyester resins, and cellulose resins. When these resins are used for the purpose of improving the visibility of the image display device, those having good transparency are preferable, and methacrylic resins are more preferable in terms of transparency and easy moldability.

  Examples of the methacrylic resin include polymethyl methacrylate and an acrylic copolymer mainly composed of methyl methacrylate units.

  Specific examples of the acrylic copolymer include a copolymer of methyl methacrylate and a vinyl monomer copolymerizable therewith.

  Examples of vinyl monomers copolymerizable with methyl methacrylate include methyl acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, and (meth) acrylic acid n. -Butyl, isobutyl (meth) acrylate, t-butyl (meth) acrylate, cyclohexyl (meth) acrylate, phenyl (meth) acrylate, benzyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, ( Examples include (meth) acrylic acid esters other than methyl methacrylate such as 2-hydroxyethyl methacrylate.

  In the present invention, “(meth) acryl” means “acryl” or “methacryl”.

  Examples of the shape of the sheet-like substrate include a molded product, a film, and a plate-like material, and can be selected according to the application. When the matte sheet is used for a front plate or the like of an image display device, a plate-like material is preferable.

  When the sheet-like substrate is a methacrylic resin plate, the thickness is preferably 0.5 to 50 mm. The thickness of the methacrylic resin plate is 0.5 mm or more, the rigidity of the sheet-like substrate is high, and the handleability tends to be excellent.

  In the present invention, functional layers such as a hard coat layer, an antistatic layer, and an antireflection layer can be laminated on the surface of the sheet-like substrate depending on the purpose.

  As a method for producing a sheet-like base material, for example, a resin melt for forming a sheet-like base material is placed in a pair of opposed molds, and after the resin melt is formed, the sheet is cooled from the mold. A sheet material from which the sheet material is peeled and a monomer raw material for forming the sheet-shaped base material is introduced into a pair of opposed molds, and the monomer raw material is cast and polymerized to form a sheet from the mold The method of exfoliating a sheet and obtaining a sheet-like base material is mentioned.

  When obtaining a sheet-like substrate having a hard coat layer on one side, for example, a hard coat layer is applied by applying a hard coat layer forming raw material to at least one inner surface of a pair of opposed molds. It can be produced by a method of obtaining the above sheet-like substrate by using a hard coat layer formed by curing the forming raw material as a mold.

  As a mold used in the above method, for example, an end portion of a plate-like body formed by facing a plate-like body such as a pair of tempered glass plates, a chrome plating plate, and a stainless steel plate at a predetermined interval is used. Examples thereof include those obtained by sealing with a gasket such as soft vinyl chloride.

  Among these, continuous production is possible by using an endless belt as a plate-shaped body, making a pair of endless belts face each other at a predetermined interval, and adopting a mold having a cavity between the opposed surfaces of these endless belts. Is preferable.

  FIG. 2 is an example of a continuous production apparatus 20 for a sheet-like substrate provided with a mold 21 using the above endless belt.

  In the mold 21, the pair of endless belts 22a and 22b travel at the same speed in the same direction indicated by the arrows in FIG. 2 with the opposing surfaces 22c and 22d facing each other. Gaskets 23 that run at the same speed as the endless belts 22a and 22b are disposed on both sides in the width direction of the endless belts 22a and 22b. Accordingly, the opposed surfaces 22c and 22d of the two endless belts 22a and 22b are maintained at a predetermined interval, and injected into the space formed by the opposed surfaces 22c and 22d of the endless belts 22a and 22b and the gasket 23. The monomer raw material for forming the sheet-like base material is maintained between the opposed surfaces 22c and 22d of the endless belts 22a and 22b without leaking.

  In FIG. 2, reference numerals 24a, 24b, 24c, and 24d indicate main rollers that apply tension to the endless belts 22a and 22b, and reference numeral 25 indicates a support roller that supports the belts.

  The monomer raw material for forming the sheet-like substrate is injected between the opposing surfaces 22c and 22d of the endless belts 22a and 22b forming the cavity from the left end side in FIG. 2, and injected according to the travel of the endless belts 22a and 22b. The monomer raw material for forming the sheet-like substrate is heated and polymerized by the hot water spray 27 in the first heating zone 26. Next, the second heating zone 28 is heat-treated with a heat source such as an air furnace or a far infrared heater to complete the polymerization. Then, it cools to predetermined temperature in the cooling zone 29, and a sheet-like base material is obtained. The obtained sheet-like base material is peeled off from the opposing surfaces 22c and 22d of the endless belts 22a and 22b and taken out.

  Examples of the material of the endless belts 22a and 22b include stainless steel and aluminum steel.

  Examples of the material of the gasket 23 include soft vinyl chloride resin, polyethylene, ethylene vinyl acetate copolymer, and polyurethane.

  Specific examples of the sheet-like substrate include a methacrylic resin plate (manufactured by Mitsubishi Rayon Co., Ltd., trade name: Acrylite MR) manufactured by a continuous casting method and having a hard coat layer formed on one surface. .

Active energy ray curable composition As an active energy ray curable composition used by this invention, polymeric compound (a-1) which has at least 2 (meth) acryloyloxy group in a molecule | numerator is 100 masses, for example. Part and a photoinitiator (a-2) 0.1-10 mass parts (with respect to 100 mass parts of compounds (a-1)) are mentioned.

  The polymerizable compound (a-1) is a cross-linking reactive compound having at least two (meth) acryloyloxy groups in the molecule, and the residue bonding each (meth) acryloyloxy group is a hydrocarbon or a derivative thereof. In the molecule, an ether bond, a thioether bond, an ester bond, an amide bond, a urethane bond and the like can be included.

  Specific examples of the polymerizable compound (a-1) include esterified products obtained from 1 mol of polyhydric alcohol and 2 mol or more of (meth) acrylic acid or a derivative thereof; and polyhydric alcohol and polycarboxylic acid or Examples thereof include linear esterified compounds having two or more (meth) acryloyloxy groups in one molecule obtained from the anhydride and (meth) acrylic acid or a derivative thereof.

  Examples of the ester obtained from 1 mol of polyhydric alcohol and 2 mol or more of (meth) acrylic acid include polyethylene glycol di (meth) acrylate such as diethylene glycol di (meth) acrylate and triethylene glycol di (meth) acrylate. 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, trimethylolethane tri (meth) acrylate, pentaglycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, Glycerin tri (meth) acrylate, dipentaerythritol tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, tripentaerythritol tetra (meth) acrylate and tripentaeryth Penta (meth) acrylate.

  A polyvalent carboxylic acid which is a raw material for a linear esterified product having two or more (meth) acryloyloxy groups in one molecule obtained from a polyhydric alcohol and a polyvalent carboxylic acid or anhydride thereof and (meth) acrylic acid As a combination of an acid or its anhydride, a polyhydric alcohol, and (meth) acrylic acid (polycarboxylic acid or its anhydride / polyhydric alcohol / (meth) acrylic acid), malonic acid / trimethylolethane / (meth) Acrylic acid, malonic acid / trimethylolpropane / (meth) acrylic acid, succinic acid / trimethylolethane / (meth) acrylic acid, succinic acid / trimethylolpropane / (meth) acrylic acid, adipic acid / trimethylolethane / ( (Meth) acrylic acid, adipic acid / trimethylolpropane / (meth) acrylic acid, glutaric acid / trimethylol Tan / (meth) acrylic acid, glutaric acid / trimethylolpropane / (meth) acrylic acid, sebacic acid / trimethylolethane / (meth) acrylic acid, sebacic acid / trimethylolpropane / (meth) acrylic acid, fumaric acid / Trimethylolethane / (meth) acrylic acid, fumaric acid / trimethylolpropane / (meth) acrylic acid, itaconic acid / trimethylolethane / (meth) acrylic acid, itaconic acid / trimethylolpropane / (meth) acrylic acid, anhydrous Mention may be made of maleic acid / trimethylolethane / (meth) acrylic acid and maleic anhydride / trimethylolpropane / (meth) acrylic acid.

  Other examples of the polymerizable compound (a-1) include polyisocyanates such as trimethylolpropane toluylene diisocyanate, hexamethylene diisocyanate, tolylene diisocyanate, 2-hydroxyethyl (meth) acrylate, and 2-hydroxypropyl (meth). Urethane poly (meth) acrylate obtained by reacting an acrylic monomer having active hydrogen such as acrylate, 2-hydroxy-3-methoxypropyl (meth) acrylate, N-methylol (meth) acrylamide, etc .; Tris (2- Examples include poly [(meth) acryloyloxyethylene] isocyanurate and epoxy polyacrylate such as di (meth) acrylate of hydroxyethyl) isocyanuric acid and tri (meth) acrylate.

  The said polymeric compound (a-1) can be used individually or in combination of 2 or more types.

  Examples of the photopolymerization initiator (a-2) include benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, acetoin, butyroin, toluoin, benzophenone, p-methoxybenzophenone, 2,2-di Carbonyl compounds such as ethoxyacetophenone and α, α-dimethoxy-α-phenylacetophenone; sulfur compounds such as tetramethylthiuram monosulfide and tetramethylthiuram disulfide; and 2,4,6-trimethylbenzoyldiphenylphosphine oxide, benzoyldiethoxy Examples thereof include phosphorus compounds such as phosphine oxide.

  As addition amount of a photoinitiator (a-2), 0.1-10 mass parts is preferable with respect to 100 mass parts of polymeric compounds (a-1). When the addition amount of the photopolymerization initiator (a-2) is 0.1 parts by mass or more, the curability of the active energy ray-curable composition tends to be improved. Moreover, when the addition amount of a photoinitiator (a-2) is 10 mass parts or less, it exists in the tendency for an active energy ray curable composition hardened layer to be hard to color. A photoinitiator (a-2) can be used individually or can use 2 or more types together.

  Various additives such as surfactants, leveling agents, dyes, pigments, antioxidants, ultraviolet absorbers, stabilizers, flame retardants, and plasticizers are blended in the active energy ray-curable composition according to the purpose. be able to.

  The compounding amount of the additive can be appropriately selected within the range in which the physical properties of the obtained active energy ray-curable composition cured layer are not impaired, but the polymerizable compound (a-1) and the photopolymerization initiator (a-2). 10 parts by mass or less is preferable with respect to 100 parts by mass in total.

Active energy ray-curable composition-coated layer The active energy ray-curable composition-coated layer is a layer formed by applying an active energy ray-curable composition to at least one surface of a sheet-like substrate.

Active energy ray curable composition coating layer forming step In the active energy ray curable composition coating layer forming step, an active energy ray curable composition coating layer is formed on at least one surface of the sheet-like substrate.

  Examples of the method for forming the active energy ray-curable composition coating layer include the same method as the coating solution coating layer forming method.

This laminated body In this invention, this laminated body is a melamine resin curing of a laminated film on the surface having an active energy ray-curable composition coating layer of a sheet-like substrate having an active energy ray-curable composition coating layer. A sheet-like substrate having an active energy ray-curable composition coating layer and a laminated film are laminated so that the layers are in contact with each other.

Laminate Forming Step In the present invention, in the laminate forming step, the surface having the active energy ray curable composition coating layer of the sheet-like substrate having the active energy ray curable composition coating layer and the melamine of the laminate film This laminated body is obtained by bonding together the surface which has the uneven | corrugated shape in which the system resin cured layer was formed.

  As a method for producing this laminate, for example, an active energy ray-curable composition coating layer is formed by applying an active energy ray-curable composition to the surface of a sheet-like substrate, and then active energy rays. Using a press roll so that the surface having a concavo-convex shape on which the melamine-based resin cured layer is formed is in contact with the active energy ray-curable composition coated layer on the curable composition coated layer The method of bonding and obtaining this laminated body is mentioned.

Active energy ray curable composition cured layer The active energy ray curable composition cured layer is obtained by curing the active energy ray curable composition coating layer.

Active energy ray curable composition cured layer-containing laminate Active energy ray curable composition cured layer-containing laminate is obtained by sequentially laminating an active energy ray curable composition cured layer and a laminated film on the surface of a sheet-like substrate. is there.

Active energy ray-curable composition cured layer-containing laminate forming step In the active energy ray-curable composition cured layer-containing laminate forming step of the present invention, active energy is applied to the active energy ray-curable composition-coated layer of the laminate. An active energy ray-curable composition cured layer is formed by irradiating a line to cure the active energy ray-curable composition, whereby an active energy ray-curable composition-cured layer-containing laminate is obtained.

  Examples of the active energy rays include ultraviolet rays and electron beams.

  Examples of the light source in the case of using ultraviolet rays as the active energy ray include a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light, and a metal halide lamp.

  As a light source in the case of using an electron beam as an active energy ray, for example, a Cockloftwald type, a bandegraph type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type and a high frequency type electron beam accelerator What was used is mentioned.

  Examples of the method of irradiating the active layer with active energy rays include a method of irradiating from at least one selected from the sheet-like substrate side and the laminated sheet side of the laminate, and can be selected according to the purpose.

  As the curing conditions for the active energy ray-curable composition, the temperature of the sheet-like substrate is 50 to 90 ° C., and the active energy ray-curable composition is applied 10 to 90 seconds after the surface of the sheet-like substrate is applied. Conditions for irradiating energy rays are preferred.

  When the temperature of the sheet-like substrate is 50 ° C. or higher, the adhesiveness between the active energy ray-curable composition cured layer and the sheet-like substrate tends to be good. Moreover, it exists in the tendency for the deformation | transformation by the heat | fever of a sheet-like base material to be suppressed when the temperature of a sheet-like base material is 90 degrees C or less.

  The time from application of the active energy ray-curable composition to the surface of the sheet-like substrate to irradiation with the active energy ray is 10 seconds or more, and the active energy ray-curable composition cured layer, the sheet-like substrate, The adhesiveness tends to be good, and the productivity tends to be good in 90 seconds or less.

  Examples of the method for heating the sheet-like substrate include a method of exposing to a hot air and a method of irradiating infrared rays.

The matte sheet The matte sheet has an uneven shape formed on the surface of the laminated film, and the cured layer of the active energy ray-curable composition having the same uneven shape as the laminated film has a sheet-like base. It is laminated on the surface of the material.

  The surface of the matte sheet has an uneven shape. The concavo-convex shape has a pitch between concavo-convex of 1 to 30 μm (Sm), a surface roughness (Ra) of 100 to 200 nm, a maximum height roughness (Rz) of 200 to 700 nm, and an average inclination of surface concavoconvex of 2 to 5 °. (Δa) is preferred.

  When the pitch (Sm) between the irregularities on the surface of the matte sheet is 1 μm or more, whitening of the matte sheet is suppressed, and when it is 30 μm or less, glare of the matte sheet tends to be suppressed.

  Moreover, when the surface roughness (Ra) is 100 nm or more, the anti-glare property of the matte sheet is good, and when it is 200 nm or less, whitening tends to be suppressed.

  Furthermore, when the maximum height roughness (Rz) is 200 nm or more, the antiglare property of the matte sheet is good, and when it is 700 nm or less, the whitening of the matte sheet tends to be suppressed.

  Further, when the average inclination (Δa) of the surface irregularities is 2 ° or more, the antiglare property of the matte sheet is good, and when the average inclination (Δa) is 5 ° or less, the whitishness of the matte sheet tends to be good.

Matting sheet forming step In the present invention, the sheet is formed by peeling the laminated film from the active energy ray-curable composition-cured layer-containing laminate obtained in the active energy ray-curable composition-cured layer-containing laminate-forming step. The matte sheet is obtained by laminating a cured layer of the active energy ray-curable composition having a concavo-convex shape formed on the surface of the substrate.

  There is no restriction | limiting in particular as a peeling method of a laminated | multilayer film from an active energy ray-curable composition cured layer containing laminated body, The mold release property of a laminated | multilayer film and an active energy ray-curable composition cured layer is favorable, and a mat film The matte sheet can be easily obtained because the adhesiveness between the curable resin and the melamine resin cured layer is good.

  The mat sheet obtained by the present invention can be used as a front plate of an image display device, a surface protection resin sheet for a solar cell module, and the like.

  Hereinafter, the present invention will be described with reference to examples.

  In the following, “parts” and “%” indicate “parts by mass” and “% by mass”, respectively.

Moreover, the abbreviation used shows the following.
C6DA: 1,6-hexanediol diacrylate (trade name, manufactured by Osaka Organic Chemical Industry Co., Ltd.)
TAS: Condensed ester of trimethylolethane, acrylic acid and succinic anhydride (trade name, manufactured by Osaka Organic Chemical Industry Co., Ltd.)
APO: Trimethylbenzoyldiphenylphosphine oxide (trade name, manufactured by BASF Japan Ltd.)
I184: Hydroxycyclohexyl phenyl ketone (manufactured by Ciba Specialty Chemicals)
U-6HA: NK ester U-6HA (manufactured by Shin-Nakamura Chemical Co., Ltd., trade name)
DPHA: Dipentaerythritol hexaacrylate (manufactured by Toa Gosei Co., Ltd.)
M305: Pentaerythritol triacrylate (trade name, manufactured by Toa Gosei Co., Ltd.)
BYK-UV3570: Multifunctional silicone-based acrylate (BIC Chemie Japan Co., Ltd., trade name)
In the following, the unevenness of the surfaces of the matte film, the laminated film and the matte sheet, the image visibility of the matte sheet and the peelability of the laminate film were evaluated by the following methods.
(1) Concave and convex shape Data obtained using NewView 6300 (trade name) manufactured by Zygo as an optical interference type surface shape measuring instrument is analyzed by data analysis software MetroPro (trade name) manufactured by Zygo, and film or The surface roughness (Ra), the maximum height roughness (Rz), the average slope (Δa) of the surface irregularities and the pitch between the irregularities (Sm) were determined.
(2) Image Visibility Image visibility when a matte sheet was used in a liquid crystal display device was evaluated by the following method.

  First, the matte surface of the liquid crystal display device (PSP2000IS (trade name) manufactured by Sony Corporation, 4.3 inch liquid crystal screen) is matted so that the surface having the uneven shape becomes an upper surface through water. A sheet was pasted.

  Next, a fluorescent lamp is installed at a height of 30 cm from the desk in a dark room, and the incident angle from the fluorescent lamp to the matte sheet is approximately 45 degrees at a position 30 cm horizontally from directly under the fluorescent lamp on the desk. As described above, a liquid crystal display device on which the matte sheet was attached was installed.

  As the image visibility of the liquid crystal display device installed in the above state, whitening, glare, character clarity, and antiglare properties were evaluated under the following conditions.

In addition, if an air layer exists between the matte sheet and the liquid crystal screen surface, the image visibility cannot be correctly evaluated due to the influence of reflected light between the liquid crystal screen side surface of the matte sheet and the air layer. Water was sandwiched between the liquid crystal screen surface and the sample for evaluation, and the influence of reflected light was removed by removing air.
(2a) Whitish A black image was displayed on the liquid crystal screen, the image was observed from a height of 30 cm in a direction substantially perpendicular to the surface of the liquid crystal screen, and the presence or absence of whitening of the black image was visually evaluated. .
(Double-circle): Black looks clear without discoloring.
○: Black appears slightly whitish.
Δ: Black looks whitish.
X: The black color is hardly visible, and it looks quite whitish.
(2b) Glare Except for displaying a green image on the liquid crystal liquid crystal screen, the presence or absence of whitening of the green image was visually evaluated in the same manner as the whitening evaluation.
A: Screen glare cannot be confirmed.
○: Some glare on the screen is recognized.
X: Screen glare is noticeable.
(2c) Character sharpness Black characters were displayed on a liquid crystal screen on a white background, images were observed from a height of 30 cm in a direction substantially perpendicular to the surface of the liquid crystal screen, and the sharpness of the characters was visually evaluated.
A: The outline of a character can be clearly observed, and blurring cannot be confirmed.
○: Some blurring is observed in the outline of the character.
Δ: The outline of the character is blurred.
X: It is difficult to observe the outline of the character.
(2d) Anti-glare A black image is displayed on the liquid crystal screen, the image is observed from a direction of approximately 45 degrees with respect to the surface of the liquid crystal screen, and the presence or absence of blurring of the fluorescent lamp image reflected on the matte sheet surface is visually observed. evaluated.
A: The blur of the fluorescent lamp image can be clearly confirmed.
○: Some blurring of fluorescent lamp image is recognized.
X: Blur of fluorescent lamp image cannot be confirmed.
(3) Peelability The peelability of the laminated film is determined by peeling the laminated film by hand after curing the active energy ray-curable composition by irradiating ultraviolet rays to form an active energy ray-curable composition cured layer. It evaluated by the ease of peeling at the time.
◯: All laminated films can be peeled without resistance.
X: At least a part of the laminated film remains adhered, and the laminated film cannot be peeled cleanly.

[Example 1]
(1) Production of laminated film Glass having an average particle diameter of about 25 μm is applied to a roll-shaped member having a thickness of 300 μm copper plated on the outer peripheral surface of a roll-shaped iron member having a diameter of 200 mm and a length of 600 mm and further nickel-plated. The beads were sprayed at an ejection pressure of 0.3 MPa to obtain a mold. Next, the active energy ray-curable composition is applied to the surface of the PET film having a thickness of 100 μm, brought into contact with the uneven surface of the mold, and irradiated with ultraviolet rays through the PET film to cure the active energy ray-curable composition. Then, it was peeled from the mold to obtain a matte film. Here, the composition of the active energy ray-curable composition is the same as that described in (2) Preparation of matte sheet in the next section. The surface roughness (Ra) was 120 nm, the maximum height roughness (Rz) was 490 nm, the average slope of the surface roughness (Δa) was 5.4 °, and the pitch between the irregularities (Sm) was 13 μm. Met. Subsequently, the surface having the concavo-convex shape of the mat film was subjected to corona treatment at a conveying speed of 4.0 m / min using a corona treatment device (manufactured by POLYDINE, 3DT). Thereafter, a coating solution having the following composition was applied to the surface of the corona-treated film having an uneven shape with a No. 4 bar coater, and then dried and cured in a dryer at 100 ° C. for 1 hour to obtain a thickness of 9. A laminated film having a 16 μm melamine-based resin cured layer was produced.
<Composition of coating solution>
(A) Melamine resin composition Melamine resin (manufactured by Harima Kasei Co., Ltd., SM975 (trade name)): 2.7 parts acrylic resin (manufactured by Mitsubishi Rayon Co., Ltd., Dianar HR656 (trade name)): 0. 3 parts curing accelerator (manufactured by DIC Corporation, P-198 (trade name)): 0.2 part (b) organic solvent acetone: 97 parts (2) Preparation of matte sheet 2 mm in thickness as a sheet-like substrate Methacrylic resin plates (trade name: Acrylite L, manufactured by Mitsubishi Rayon Co., Ltd.) were used. This sheet-like substrate was heated in a dryer at 80 ° C. for 30 minutes.

  Next, after applying the active energy ray-curable composition having the following composition to the surface of the sheet-like substrate, the press roll is placed so that the surface having the uneven shape of the laminated film is in contact with the active energy ray-curable composition. The active energy ray-curable composition coating layer was sandwiched between laminated films.

  30 seconds after applying the active energy ray-curable composition, the active energy ray-curable composition is cured by irradiating ultraviolet rays at 13.8 kW for 60 seconds using a metal halide lamp to cure the active energy ray-curable composition. After forming the composition cured layer, the laminated film was peeled off to obtain a matte sheet.

Table 1 shows the evaluation results of the matte film, the laminated film, and the matte sheet.
<Composition of active energy ray-curable composition>
C6DA: 50 parts TAS: 50 parts APO: 2 parts I184: 2 parts

[Example 2]
A laminated film and a matte sheet were prepared and evaluated in the same manner as in Example 1 except that the composition of the coating solution was changed to 0.9 part for SM975, 0.1 part for Dianal HR656 and 99 parts for acetone. Carried out. The evaluation results are shown in Table 1.

[Example 3]
A matte film was prepared in the same manner as in Example 1 except that the pressure for spraying the glass beads on the SUS roll was 0.25 MPa. The surface roughness (Ra) is 220 nm, the maximum height roughness (Rz) is 940 nm, the average slope of the surface roughness (Δa) is 7.1 °, and the pitch between the irregularities (Sm) is 19 μm. there were. Next, a laminated film and a matte sheet were produced in the same manner as in Example 2 and evaluated. The evaluation results are shown in Table 1.

[Example 4]
A laminated film and a matte sheet were produced and evaluated in the same manner as in Example 1 except that the same matte film as in Example 3 was used. The evaluation results are shown in Table 1.

[Example 5]
A matte film was prepared in the same manner as in Example 1 except that the pressure for spraying the glass beads on the SUS roll was 0.15 MPa. The surface roughness (Ra) is 180 nm, the maximum height roughness (Rz) is 700 nm, the average slope of surface irregularities (Δa) is 7.2 °, and the pitch between irregularities (Sm) is 16 μm. there were. Next, a laminated film and a matte sheet were produced in the same manner as in Example 2 and evaluated. The evaluation results are shown in Table 1.

[Example 6]
A laminated film and a matte sheet were prepared and evaluated in the same manner as in Example 1 except that the same matte film as in Example 5 was used. The evaluation results are shown in Table 1.

[Example 7]
The composition of the coating solution was changed to 4.5 parts for SM975, 0.5 parts for Dianar HR656 and 95 parts for acetone, and a matte film having a surface roughness (Ra) of 404 nm and a maximum height roughness (Rz) of 2 260 nm, average slope of surface irregularities (Δa) 18 ° and pitch between irregularities (Sm) of 8.3 μm (except for using SMAT (trade name) manufactured by Goyo Paper Industries Co., Ltd.) A laminated film and a matte sheet were produced in the same manner as in Example 1 and evaluated. The evaluation results are shown in Table 1.

[Comparative Example 1]
A laminated film was prepared in the same manner as in Example 7 except that a surface having an uneven shape as the matte film was not subjected to corona discharge treatment, and after the active energy ray-curable composition cured layer was formed, the laminated film was An attempt was made to peel off, but the laminated film could not be peeled off. The evaluation results are shown in Table 1.

[Comparative Example 2]
A laminated film was prepared in the same manner as in Example 1 except that a matte film having a concavo-convex shape and not subjected to corona discharge treatment was used, and after the active energy ray-curable composition cured layer was formed, the laminated film was An attempt was made to peel off, but the laminated film could not be peeled off. The evaluation results are shown in Table 1.

[Comparative Example 3]
Matte film having a surface roughness (Ra) of 140 nm, a maximum height roughness (Rz) of 816 nm, an average slope of surface irregularities (Δa) of 2.1 ° and a pitch between irregularities (Sm) of 51 μm (manufactured by Goyo Paper Industries Co., Ltd., A curable composition solution having the following composition was applied to the surface of TMAT (trade name) with a No. 4 bar coater, dried in an atmosphere of 100 ° C. for 60 minutes, and then subjected to 60 at a metal halide lamp of 13.8 kW. A laminated film having a cured product layer of a curable composition having a thickness of 0.5 μm was prepared by curing for 2 seconds.

The laminated film was used, and after the active energy ray-curable composition cured layer was formed in the same manner as in Example 1, an attempt was made to peel the laminated film, but the laminated film could not be peeled. The evaluation results are shown in Table 1.
<Composition of curable composition solution>
(A) Curable composition U-6HA: 2.5 parts C6DA: 2.5 parts I184: 2 parts (b) Organic solvent toluene: 93 parts

[Comparative Example 4]
The laminated film was peeled off after the active energy ray-curable composition cured layer was formed in the same manner as in Comparative Example 3 except that the following composition was used as the composition of the curable composition solution. Could not be peeled off. The evaluation results are shown in Table 1.
<Composition of curable composition solution>
(A) Curable composition DPHA: 4.1 parts M305: 0.7 parts I184: 0.2 parts (b) Organic solvent toluene: 95 parts

[Comparative Example 5]
The laminated film was peeled off after the active energy ray-curable composition cured layer was formed in the same manner as in Comparative Example 3 except that the following composition was used as the composition of the curable composition solution. Could not be peeled off. The evaluation results are shown in Table 1.
<Composition of curable composition solution>
(A) Curable composition BYK-UV3570: 4.75 parts I184: 0.25 parts (b) Organic solvent toluene: 95 parts

11: Laminated film 11a: Matte film 11b: Melamine resin cured layer 20: Continuous production apparatus for sheet-like substrate 21: Mold 22a, 22b: Endless belt 22c, 22d: Opposing surface of endless belt 22a, 22b 23: Gasket 24a 24b, 24c, 24d: main roller 25: support roller

Claims (1)

A method for producing a matte sheet having the following steps (1) to (7), wherein a matte active energy ray-curable composition cured layer having an uneven shape is laminated on at least one surface of a sheet-like substrate. Sheet manufacturing method.
(1) A mat film surface treatment step for subjecting the surface of the mat film having an uneven shape to at least one surface to a discharge gas. (2) For coating containing a melamine-based resin composition on the surface of the surface-treated mat film. A coating solution coating layer forming step of coating the solution to form a coating solution coating layer on the surface of the mat film (3) The mat is cured by curing the melamine resin composition in the coating solution coating layer. A laminated film forming step for forming a laminated film having a concavo-convex shape in which a melamine-based resin cured layer is laminated on the surface of the film (4) An active energy ray-curable composition is applied to at least one surface of a sheet-like substrate Active energy ray-curable composition coating layer forming step for forming an active energy ray-curable composition coating layer on the surface of the sheet-like substrate (5) Active energy ray hardness of the sheet-like substrate A laminate of a laminated film and a sheet-like substrate having an active energy ray-curable composition-coated layer is bonded to the surface of the laminated film on which the melamine-based resin cured layer is formed. Laminate formation step to be formed (6) Active energy ray curable composition coating layer from at least one of upper surface or lower surface of laminate of sheet-like base material and laminated film having active energy ray curable composition coating layer Active energy ray curable composition coating layer is cured by irradiating active energy ray to form active energy ray curable composition cured layer-containing laminate having active energy ray curable composition cured layer Line curable composition cured layer-containing laminate formation step (7) surface by peeling the laminated film from the active energy ray curable composition cured layer-containing laminate Matte sheet forming step of the active energy ray-curable composition cured layer having irregularities forming a matte sheet laminated

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