JP5837970B2 - Method for producing hydrophilic laminate, method for producing article, and antifouling method - Google Patents

Description

  The present invention has hydrophilicity and can be used in a wide range of building applications, industrial applications, automotive applications, optical applications, solar battery panels, etc., and can be easily molded, and its manufacturing method, the hydrophilic property The present invention relates to an antifouling laminate using a laminate, an article using the hydrophilic laminate, a production method thereof, and an antifouling method using the hydrophilic laminate.

In order to decorate and protect the surface of various articles, a resin film, glass, or the like is attached to the surface.
However, the visibility and aesthetics of the article may deteriorate due to fogging and soiling of resin films, glass, etc. that decorate and protect the surface of the article.
Therefore, in order to prevent the visibility and aesthetics of such articles from deteriorating, the resin film and glass are subjected to a hydrophilic treatment.

  As a hydrophilic treatment technique, for example, by applying an antifogging agent containing a surfactant or the like to the surface of an object, the wettability of the coated surface with respect to water is improved and fine water droplets are not generated. Has been proposed (see, for example, Patent Document 1). However, although this proposed technique can easily change the surface to hydrophilic, there is a problem that the effect of hydrophilization is not sustainable due to application by spraying or the like.

In addition, a technique has been proposed in which TiO ₂ having a photocatalytic function is stacked on the surface of a glass substrate and the photocatalytic activity of the TiO ₂ is used (see, for example, Patent Document 2). However, the proposed technique requires a sufficient amount of ultraviolet rays to develop the photocatalytic function, and thus has a problem that the usable place is restricted.

  In addition, as a technique for improving the hydrophilicity of the surface of the transparent substrate, a technique for forming a film on the substrate and hydrophilizing by forming a fine uneven surface uniformly with an inorganic powder added to the film Has been proposed (see, for example, Patent Document 3). In this proposed technique, a dispersion containing silicon dioxide fine powder is applied to soda glass and heated and cured. However, the condition is 120 ° C. for 30 minutes, and there is a problem that the substrate is restricted. is there.

  In addition, as a structure in which hydrophilicity is maintained for a long period of time, a technique has been proposed in which unevenness is formed on a silicon plate or glass by photolithography and etching, and the uneven surface is oxidized to be hydrophilic (for example, , See Patent Document 4). However, this proposed technique has a problem that it cannot be applied to a resin base material.

  In addition, a technique for maintaining hydrophilicity with a nanometer-sized fine structure has been proposed (see, for example, Patent Document 5). However, in this proposed technique, the disclosure regarding hydrophilicity is limited to those in which the base material is glass, such as a front window and a side window for automobiles, and the hydrophilicity of a resin base material such as acrylic resin. Is not disclosed.

  Therefore, even when a resin base material that can be easily processed is used, a hydrophilic laminate that can maintain hydrophilicity over a long period of time without being restricted by a usable place, a method for producing the same, and the hydrophilic laminate The present condition is that provision of an antifouling laminate using a body, an article using the hydrophilic laminate, a method for producing the same, and an antifouling method using the hydrophilic laminate is required.

JP 2004-263008 A JP 2002-201045 A JP-A-11-217560 JP 2001-221966 A JP 2007-187868 A

  An object of the present invention is to solve the above-described problems and achieve the following objects. That is, the present invention is a hydrophilic laminate capable of maintaining hydrophilicity over a long period of time, even when using a resin base material that can be easily processed, and a manufacturing method thereof, An object of the present invention is to provide an antifouling laminate using the hydrophilic laminate, an article using the hydrophilic laminate, a production method thereof, and an antifouling method using the hydrophilic laminate.

Means for solving the problems are as follows. That is,
<1> A resin base material and a hydrophilic resin layer on the resin base material,
The hydrophilic resin layer has either a fine convex part or a concave part on the surface,
A hydrophilic laminate having a pure water contact angle on the surface of the hydrophilic resin layer of less than 40 ° C.
<2> The hydrophilic laminate according to <1>, wherein the elongation percentage is 10% or more.
<3> Martens hardness of the hydrophilic resin layer ^is a hydrophilic laminate according to any one of <2>, wherein a ^{50N / mm 2 ~300N / mm 2} <1>.
<4> The hydrophilic laminate according to any one of <1> to <3>, wherein the hydrophilic resin layer contains a cured product of an active energy ray-curable resin composition containing polyethylene glycol (meth) acrylate. It is.
<5> An antifouling laminate comprising the hydrophilic laminate according to any one of <1> to <4>.
<6> The method for producing a hydrophilic laminate according to any one of <1> to <4>,
An uncured resin layer forming step of forming an uncured resin layer by applying an active energy ray-curable resin composition on a resin substrate;
Adhering a transfer master having either a fine convex part or a concave to the uncured resin layer, irradiating the uncured resin layer to which the transfer master is in contact with an active energy ray to cure the uncured resin layer And a hydrophilic resin layer forming step of forming a hydrophilic resin layer by transferring any of the fine convex portions and concave portions.
<7> The hydrophilicity according to <6>, wherein any one of the fine convex portion and the concave portion of the transfer master is formed by etching the surface of the transfer master using a photoresist having a predetermined pattern shape as a protective film. Is a method for producing a conductive laminate.
<8> The hydrophilic laminate according to <6>, wherein any one of the fine convex portion and the concave portion of the transfer master is formed by irradiating the surface of the transfer master with laser processing of the transfer master. It is a manufacturing method of a body.
<9> An article having the hydrophilic laminate according to any one of <1> to <4> on a surface thereof.
<10> The method for producing an article according to <9>,
A heating step for heating the hydrophilic laminate,
A hydrophilic laminate forming step of forming the heated hydrophilic laminate into a desired shape;
An injection molding step of injecting a molding material onto the resin base material side of the hydrophilic laminate formed into a desired shape and molding the molding material.
<11> The method for manufacturing an article according to <10>, wherein the heating in the heating step is performed by infrared heating.
<12> An antifouling method characterized by preventing the article from being soiled by laminating the hydrophilic laminate according to any one of <1> to <4> on the surface of the article.

  According to the present invention, the conventional problems can be solved, the object can be achieved, and even when a resin base material that is easy to process is used, there is no restriction on the place where it can be used, Hydrophilic laminate that can maintain hydrophilicity over time, a method for producing the same, an antifouling laminate using the hydrophilic laminate, an article using the hydrophilic laminate, a method for producing the same, and the hydrophilic An antifouling method using a conductive laminate can be provided.

FIG. 1A is an atomic force microscope (AFM) image showing an example of the surface of a hydrophilic resin layer having convex portions. 1B is a cross-sectional view taken along the line aa in FIG. 1A. FIG. 2A is an AFM image showing an example of the surface of a hydrophilic resin layer having a recess. 2B is a cross-sectional view taken along line aa in FIG. 2A. FIG. 3A is a perspective view illustrating an example of a configuration of a roll master that is a transfer master. 3B is an enlarged plan view showing a part of the roll master shown in FIG. 3A. 3C is a cross-sectional view of the track T in FIG. 3B. FIG. 4 is a schematic diagram showing an example of the configuration of a roll master exposure apparatus for producing a roll master. FIG. 5A is a process diagram for explaining an example of a process for producing a roll master. FIG. 5B is a process diagram for explaining an example of a process for producing a roll master. FIG. 5C is a process diagram for explaining an example of a process for producing a roll master. FIG. 5D is a process diagram for explaining an example of a process for producing a roll master. FIG. 5E is a process diagram for explaining an example of a process for producing a roll master. FIG. 6A is a process diagram for explaining an example of a process of transferring fine convex portions or concave portions by a roll master. FIG. 6B is a process diagram for explaining an example of a process of transferring a fine convex portion or a concave portion with a roll master. FIG. 6C is a process diagram for explaining an example of a process of transferring a fine convex portion or a concave portion with a roll master. FIG. 7A is a plan view illustrating an example of a configuration of a plate-shaped master that is a transfer master. FIG. 7B is a cross-sectional view taken along the line aa shown in FIG. 7A. FIG. 7C is an enlarged cross-sectional view of a part of FIG. 7B. FIG. 8 is a schematic diagram showing an example of the configuration of a laser processing apparatus for producing a plate-shaped master. FIG. 9A is a process diagram for explaining an example of a process for producing a plate-shaped master. FIG. 9B is a process diagram for explaining an example of a process for producing a plate-shaped master. FIG. 9C is a process diagram for explaining an example of a process for producing a plate-shaped master. FIG. 10A is a process diagram for explaining an example of a process of transferring fine convex portions or concave portions with a plate-shaped master. FIG. 10B is a process diagram for explaining an example of a process of transferring fine convex portions or concave portions by a plate-shaped master. FIG. 10C is a process diagram for explaining an example of a process of transferring a fine convex portion or a concave portion with a plate-shaped master. FIG. 11A is a process diagram for explaining an example of manufacturing the article of the present invention by in-mold molding. FIG. 11B is a process diagram for explaining an example of manufacturing the article of the present invention by in-mold molding. FIG. 11C is a process diagram for explaining an example of manufacturing the article of the present invention by in-mold molding. FIG. 11D is a process diagram for explaining an example of producing the article of the present invention by in-mold molding. FIG. 11E is a process diagram for explaining an example of producing the article of the present invention by in-mold molding. FIG. 11F is a process diagram for explaining an example of manufacturing the article of the present invention by in-mold molding. 12A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 1. FIG. 12B is a cross-sectional view taken along line aa in FIG. 12A. 13A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 2. FIG. 13B is a cross-sectional view taken along the line aa in FIG. 13A. 14A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 3. FIG. 14B is a cross-sectional view taken along line aa in FIG. 14A. 15A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 4. FIG. 15B is a cross-sectional view taken along line aa in FIG. 15A. 16A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 5. FIG. 16B is a cross-sectional view taken along the line aa in FIG. 16A. FIG. 17A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 6. FIG. 17B is a cross-sectional view taken along the line aa in FIG. 17A. 18A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 7. FIG. 18B is a cross-sectional view taken along line aa in FIG. 18A. FIG. 19A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 8. 19B is a cross-sectional view taken along the line aa in FIG. 19A. 20A is an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate of Example 9. FIG. 20B is a cross-sectional view taken along the line aa in FIG. 20A.

(Hydrophilic laminate)
The hydrophilic laminated body of this invention has a resin-made base material and a hydrophilic resin layer at least, and also has another member as needed.

<Resin base material>
There is no restriction | limiting in particular as a material of the said resin-made base materials, According to the objective, it can select suitably, For example, a triacetyl cellulose (TAC), polyester (TPEE), a polyethylene terephthalate (PET), a polyethylene naphthalate ( PEN), polyimide (PI), polyamide (PA), aramid, polyethylene (PE), polyacrylate, polyether sulfone, polysulfone, polypropylene (PP), polystyrene, diacetyl cellulose, polyvinyl chloride, acrylic resin (PMMA), Polycarbonate (PC), epoxy resin, urea resin, urethane resin, melamine resin, phenol resin, acrylonitrile-butadiene-styrene copolymer, cycloolefin polymer (COP), cycloolefin copolymer (CO ), PC / PMMA laminate, such as rubber additives PMMA and the like.

  The resin base material preferably has transparency.

There is no restriction | limiting in particular as a shape of the said resin-made base materials, Although it can select suitably according to the objective, It is preferable that it is a film form.
When the resin base material is in the form of a film, the average thickness of the resin base material is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 5 μm to 1,000 μm, preferably 50 μm to 500 μm. Is more preferable.

  Characters, patterns, images, and the like may be printed on the surface of the resin substrate.

  On the surface of the resin base material, the character is derived from the flow pressure of the molding material at the time of molding, in order to increase the adhesion between the resin base material and the molding material, at the time of molding the hydrophilic laminate. In order to protect the pattern and the image, a binder layer may be provided. As the material of the binder layer, various adhesives can be used in addition to various binders such as acrylic, urethane, polyester, polyamide, ethylene butyl alcohol, and ethylene vinyl acetate copolymer systems. Two or more binder layers may be provided. As the binder to be used, one having heat sensitivity and pressure sensitivity suitable for the molding material can be selected.

<Hydrophilic resin layer>
The said hydrophilic resin layer has either a fine convex part and a recessed part on the surface.
The pure water contact angle on the surface of the hydrophilic resin layer is less than 40 °.
The hydrophilic resin layer is formed on the resin substrate.

  There is no restriction | limiting in particular as said hydrophilic resin layer, Although it can select suitably according to the objective, It is preferable to contain the hardened | cured material of an active energy ray curable resin composition.

-Fine convex portions and fine concave portions-
The hydrophilic resin layer has either a fine convex part or a concave part on its surface.
Either the fine convex part or the concave part is formed on the surface of the hydrophilic resin layer opposite to the resin base material side.

Here, the fine convex portion means that the average distance between adjacent convex portions on the surface of the hydrophilic resin layer is 1,000 nm or less.
Here, the fine recess means that the average distance between adjacent recesses on the surface of the hydrophilic resin layer is 1,000 nm or less.

  The shape of the convex portion and the concave portion is not particularly limited and can be appropriately selected depending on the purpose. For example, a cone shape, a column shape, a needle shape, or a partial shape of a sphere (for example, a hemisphere) Shape), a partial shape of an ellipsoid (for example, a semi-ellipsoidal shape), and a polygonal shape. These shapes need not be mathematically defined complete shapes, and may have some distortion.

  The convex portion or the concave portion is two-dimensionally arranged on the surface of the hydrophilic resin layer. The arrangement may be a regular arrangement or a random arrangement. The regular arrangement is preferably a close-packed structure from the viewpoint of the filling rate.

There is no restriction | limiting in particular as an average distance of the said adjacent convex part, Although it can select suitably according to the objective, 5 nm-1,000 nm are preferable, 10 nm-500 nm are more preferable, 50 nm-300 nm are especially preferable.
There is no restriction | limiting in particular as an average distance of the said adjacent recessed part, Although it can select suitably according to the objective, 5 nm-1,000 nm are preferable, 10 nm-500 nm are more preferable, 50 nm-300 nm are especially preferable.
When the average distance between the adjacent convex portions and the average distance between the adjacent concave portions are within the preferable range, the hydrophilic component attached to the hydrophilic resin layer effectively wets and spreads. When the average distance is within the particularly preferable range, the effect of spreading the hydrophilic component becomes remarkable.

There is no restriction | limiting in particular as average height of the said convex part, Although it can select suitably according to the objective, 1 nm-1,000 nm are preferable, 5 nm-500 nm are more preferable, 10 nm-300 nm are still more preferable, 50 nm ˜300 nm is particularly preferred.
There is no restriction | limiting in particular as an average depth of the said recessed part, Although it can select suitably according to the objective, 1 nm-1,000 nm are preferable, 5 nm-500 nm are more preferable, 10 nm-300 nm are still more preferable, 50 nm- 300 nm is particularly preferred.
When the average height of the convex portions and the average depth of the concave portions are within the preferable range, the hydrophilic component attached to the hydrophilic resin layer is effectively spread by wetting. When the average height and the average depth are within the particularly preferable range, the effect of spreading the hydrophilic component becomes remarkable.

As the average aspect ratio of the convex part (average height of the convex part / average distance of the adjacent convex part) and the average aspect ratio of the concave part (average depth of the concave part / average distance of the adjacent concave part) There is no particular limitation, and it can be appropriately selected according to the purpose. However, 0.001 to 1,000 is preferable, 0.1 to 10 is more preferable, and 0.2 to 1.0 is particularly preferable.
When the average aspect ratio of the convex portions and the average aspect ratio of the concave portions are within the preferable range, the hydrophilic component attached to the hydrophilic resin layer effectively wets and spreads. When the aspect ratio is in the particularly preferable range, the effect of spreading the hydrophilic component becomes remarkable.

Here, the average distance (Pm) of the convex part or the concave part, and the average height of the convex part or the average depth (Hm) of the concave part can be measured as follows.
First, the surface S of the hydrophilic resin layer having a convex portion or a concave portion is observed with an atomic force microscope (AFM), and the pitch of the convex portion or the concave portion and the height of the convex portion are determined from the cross-sectional profile of the AFM. Or the depth of a recessed part is calculated | required. This is repeated at 10 locations randomly selected from the surface of the hydrophilic resin layer, and pitches P1, P2,..., P10 and heights or depths H1, H2,. Ask for.
Here, the pitch of the convex portions is a distance between the vertices of the convex portions. The pitch of the recesses is the distance between the deepest portions of the recesses. The height of the convex portion is the height of the convex portion based on the lowest point of the valley between the convex portions. The depth of the recess is the depth of the recess based on the highest point of the peak between the recesses.
Next, these pitches P1, P2,..., P10 and the heights or depths H1, H2,..., H10 are simply averaged (arithmetic average), and the average distance between the convex portions or the concave portions is calculated. (Pm) and the average height of the convex portions or the average depth (Hm) of the concave portions are obtained.
In addition, when the pitch of the said convex part or a recessed part has in-plane anisotropy, the said Pm shall be calculated | required using the pitch of the direction where a pitch becomes the maximum. Further, when the height of the convex portion or the depth of the concave portion has in-plane anisotropy, the height or depth in the direction in which the height or depth is maximum is used. Is to be sought.
Moreover, when the said convex part or a recessed part is rod-shaped, the pitch of a short-axis direction is measured as said pitch.
In the AFM observation, the cross-sectional profile is a measurement target so that the convex vertex or concave base of the cross-sectional profile matches the vertex of the solid convex portion or the deepest portion of the concave portion. It cuts out so that it may become a cross section which passes through the top of a convex part of a solid shape, or the deepest part of a concave part of a solid shape.

Here, whether the fine shape formed on the surface of the hydrophilic resin layer is a convex portion or a concave portion can be determined as follows.
The surface S of the hydrophilic resin layer having a convex portion or a concave portion is observed with an atomic force microscope (AFM) to obtain a cross section and an AFM image of the surface S.
When the AFM image of the surface is a bright image on the outermost surface side and a dark image on the deep side, when the bright image is formed in an island shape in the dark image, the surface has a convex portion. Shall.
On the other hand, when a dark image is formed in an island shape in a bright image, the surface thereof has a recess.
For example, the surface of the hydrophilic resin layer having an AFM image of the surface and cross section shown in FIGS. 1A and 1B has a convex portion. The surface of the hydrophilic resin layer having the AFM image of the surface and cross section shown in FIGS. 2A and 2B has a recess.

There is no restriction | limiting in particular as an average surface area ratio of the surface of the said hydrophilic resin layer, Although it can select suitably according to the objective, 1.10 or more are preferable, 1.30 or more are more preferable, 1.40 or more Is particularly preferred. The surface area ratio is a ratio (surface area / area) between the surface area generated by the surface shape of the object in a specified area and the area of the specified area. When the average surface area ratio is within the preferable range, the hydrophilic component attached to the hydrophilic resin layer effectively wets and spreads. When the average surface area ratio is within the particularly preferable range, the effect of spreading the hydrophilic component becomes remarkable.
Here, the average surface area ratio of the surface of the hydrophilic resin layer can be measured as follows.
The surface S of the hydrophilic resin layer having a convex portion or a concave portion is observed with an atomic force microscope (AFM) to obtain an AFM image of the surface S. This is repeated at 10 points randomly selected from the surface of the hydrophilic resin layer, and the surface areas S1, S2,. Next, the ratio (surface area / area) SR1, SR2,..., SR10 of these surface areas S1, S2,..., S10 and the area of each observation region is simply averaged (arithmetic average). Then, the average surface area ratio SRm of the surface of the hydrophilic resin layer is obtained.

−Pure water contact angle−
The pure water contact angle on the surface of the hydrophilic resin layer is less than 40 °, preferably 20 ° or less, more preferably 15 ° or less, and particularly preferably 10 ° or less. There is no restriction | limiting in particular as a lower limit of the said pure water contact angle, According to the objective, it can select suitably, For example, 5 degrees etc. are mentioned.
The pure water contact angle can be measured by, for example, a sliding method under the following conditions using PCA-1 (manufactured by Kyowa Interface Chemical Co., Ltd.).
-Put distilled water in a plastic syringe, attach a stainless steel needle to the tip, and drop it onto the evaluation surface.
・ Drip amount of water: 2μL
・ Measurement temperature: 25 ℃

-Active energy ray-curable resin composition-
The active energy ray-curable resin composition is not particularly limited and may be appropriately selected depending on the intended purpose. For example, it contains at least a hydrophilic monomer and a photopolymerization initiator, and further if necessary. And active energy ray-curable resin compositions containing other components.

--Hydrophilic monomer--
Examples of the hydrophilic monomer include polyoxyalkyl-containing (meth) acrylate, quaternary ammonium salt-containing (meth) acrylate, tertiary amino group-containing (meth) acrylate, sulfonic acid group-containing monomer, carboxylic acid group-containing monomer, Examples thereof include phosphoric acid group-containing monomers and phosphonic acid group-containing monomers.
Here, in the present invention, (meth) acrylate means acrylate or methacrylate. The same applies to (meth) acryloyl and (meth) acryl.

The polyoxyalkyl-containing (meth) acrylate is obtained, for example, by a reaction between a polyhydric alcohol (polyol or polyhydroxy-containing compound) and a compound selected from the group consisting of acrylic acid, methacrylic acid and derivatives thereof. Mono or polyacrylate, mono or polymethacrylate, etc. may be mentioned. Examples of the polyhydric alcohol include divalent alcohol, trivalent alcohol, and tetravalent or higher alcohol. Examples of the divalent alcohol include ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol having a number average molecular weight of 300 to 1,000, propylene glycol, dipropylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, 2-ethyl-1,3-hexanediol, 2,2′-thiodiethanol, 1,4-cyclohexanedi For example, methanol. Examples of the trivalent alcohol include trimethylolethane, trimethylolpropane, pentaglycerol, glycerol, 1,2,4-butanetriol, 1,2,6-hexanetriol, and the like. Examples of the tetravalent or higher alcohol include pentaerythritol, diglycerol, and dipentaerythritol.
Examples of the polyoxyalkyl-containing (meth) acrylate include polyethylene glycol (meth) acrylate and polypropylene glycol (meth) acrylate. Examples of the polyethylene glycol (meth) acrylate include methoxypolyethylene glycol (meth) acrylate. There is no restriction | limiting in particular as the molecular weight of the polyethyleneglycol unit in the said polyethyleneglycol (meth) acrylate, According to the objective, it can select suitably, For example, 300-1,000 etc. are mentioned. A commercial item can be used as said methoxypolyethyleneglycol (meth) acrylate. As said commercial item, MEPM-1000 (made by Daiichi Kogyo Seiyaku Co., Ltd.) etc. are mentioned, for example.
Among these, polyethylene glycol (meth) acrylate is preferable, and methoxypolyethylene glycol (meth) acrylate is more preferable.

  Examples of the quaternary ammonium salt-containing (meth) acrylate include (meth) acryloyloxyethyltrimethylammonium chloride, (meth) acryloyloxyethyldimethylbenzylammonium chloride, (meth) acryloyloxyethyldimethylglycidylammonium chloride, (meth) Acryloyloxyethyltrimethylammonium methylsulfate, (meth) acryloyloxydimethylethylammonium ethylsulfate, (meth) acryloyloxyethyltrimethylammonium-p-toluenesulfonate, (meth) acrylamidopropyltrimethylammonium chloride, (meth) acrylamidopropyldimethyl Benzyl ammonium chloride, (meth) acrylamide pro Le dimethyl glycidyl chloride, (meth) acrylamide trimethyl ammonium methyl sulfate, (meth) acrylamide dimethyl ethyl ammonium ethylsulfate, and (meth) acrylamide trimethylammonium -p- toluenesulfonate.

  Examples of the tertiary amino group-containing (meth) acrylate include N, N-dimethylaminoethyl (meth) acrylate, N, N-dimethylaminopropyl (meth) acrylamide, diethylaminopropyl (meth) acrylamide, Examples include 2,6,6-pentamethylpiperidyl (meth) acrylate and 2,2,6,6-tetramethylpiperidyl (meth) acrylate.

  Examples of the sulfonic acid group-containing monomer include vinyl sulfonic acid, allyl sulfonic acid, vinyl toluene sulfonic acid, styrene sulfonic acid, and sulfonic acid group-containing (meth) acrylate. Examples of the sulfonic acid group-containing (meth) acrylate include, for example, sulfoethyl (meth) acrylate, sulfopropyl (meth) acrylate, 2-acrylamido-2-methylpropanesulfonic acid, and terminal sulfonic acid-modified polyethylene glycol mono (meth). Examples include chlorate. These may form a salt. Examples of the salt include sodium salt, potassium salt, ammonium salt and the like.

  Examples of the carboxylic acid group-containing monomer include acrylic acid and methacrylic acid.

  Examples of the phosphate group-containing monomer include (meth) acrylate having a phosphate ester.

  The hydrophilic monomer is preferably a monofunctional hydrophilic monomer.

  There is no restriction | limiting in particular as molecular weight of the said hydrophilic monomer, Although it can select suitably according to the objective, 200 or more are preferable.

  There is no restriction | limiting in particular as content of the said hydrophilic monomer in the said active energy ray curable resin composition, Although it can select suitably according to the objective, 15 mass%-99.9 mass% are preferable, 20 The mass% is more preferably 90% by mass, and particularly preferably 25% by mass to 50% by mass.

  Instead of the hydrophilic monomer, a photosensitive group containing at least one selected from an azide group, phenyl azide group, quinone azide group, stilbene group, chalcone group, diazonium base, cinnamic acid group, acrylic acid group and the like was introduced. A polymer may be used. Examples of the polymer include polyvinyl alcohol, polyvinyl butyral, polyvinyl pyrrolidone, polyacrylamide, polyvinyl acetate, polyoxyalkylene, and the like.

-Photopolymerization initiator-
Examples of the photopolymerization initiator include a photoradical polymerization initiator, a photoacid generator, a bisazide compound, hexamethoxymethylmelamine, and tetramethoxyglycolyl.
The radical photopolymerization initiator is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include ethoxyphenyl (2,4,6-trimethylbenzoyl) phosphine oxide and bis (2,6-dimethylbenzoyl). ) -2,4,4-trimethylpentylphosphine oxide, bis (2,4,6-trimethylbenzoyl) -2,4,4-trimethylpentylphosphine oxide, bis (2,6-dichlorobenzoyl) -2 , 4,4-trimethylpentylphosphine oxide, 1-phenyl 2-hydroxy-2methylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 1- (4-isopropylphenyl) -2-hydroxy-2-methylpropane -1-one, 1,2-diphenylethanedione, methylphenylglycone Kishireto and the like.

  There is no restriction | limiting in particular as content of the said photoinitiator in the said active energy ray curable resin composition, Although it can select suitably according to the objective, 0.1 mass%-10 mass% are preferable, 0.5 mass%-8 mass% are more preferable, and 1 mass%-5 mass% are especially preferable.

-Other ingredients-
There is no restriction | limiting in particular as said other component, According to the objective, it can select suitably, For example, urethane (meth) acrylate, isocyanuric acid group containing (meth) acrylate, a filler, etc. are mentioned.
These may be used to adjust the elongation rate, hardness and the like of the hydrophilic resin layer.

  There is no restriction | limiting in particular as said urethane (meth) acrylate, According to the objective, it can select suitably, For example, aliphatic urethane (meth) acrylate, aromatic urethane (meth) acrylate, etc. are mentioned. Among these, aliphatic urethane (meth) acrylate is preferable.

There is no restriction | limiting in particular as content of the said urethane (meth) acrylate in the said active energy ray curable resin composition, Although it can select suitably according to the objective, 10 mass%-45 mass% are preferable, 15 More preferred is 40% by weight, and especially preferred is 20% to 35% by weight.
There is no restriction | limiting in particular as said isocyanuric acid group containing (meth) acrylate, According to the objective, it can select suitably, For example, ethoxylated isocyanuric acid (meth) acrylate etc. are mentioned. Among these, ethoxylated isocyanuric acid (meth) acrylate is preferable.

  There is no restriction | limiting in particular as content of the said isocyanuric acid group containing (meth) acrylate in the said active energy ray curable resin composition, Although it can select suitably according to the objective, 10 mass%-45 mass% are Preferably, 15 mass%-40 mass% are more preferable, and 20 mass%-35 mass% are especially preferable.

  The filler is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include silica, zirconia, titania, tin oxide, indium tin oxide, antimony-doped tin oxide, and antimony pentoxide. Examples of the silica include solid silica and hollow silica.

  The active energy ray-curable resin composition can be diluted with an organic solvent when used. Examples of the organic solvent include aromatic solvents, alcohol solvents, ester solvents, ketone solvents, glycol ether solvents, glycol ether ester solvents, chlorine solvents, ether solvents, N-methylpyrrolidone, and dimethyl. Examples include formamide, dimethyl sulfoxide, dimethylacetamide, and the like.

  The active energy ray-curable resin composition is cured when irradiated with active energy rays. There is no restriction | limiting in particular as said active energy ray, According to the objective, it can select suitably, For example, an electron beam, an ultraviolet-ray, infrared rays, a laser beam, visible light, ionizing radiation (X ray, alpha ray, beta ray, gamma) Wire, etc.), microwave, high frequency and the like.

The Martens hardness of the hydrophilic resin layer is not particularly limited and may be appropriately selected depending on the intended ^purpose, but is preferably ^{50N / mm 2 ~300N / mm 2} , 50N / mm 2 ~290N / mm 2 is more ^{preferably, 50N / mm 2 ~280N / mm} 2 is particularly preferred. When the hydrophilic laminate is molded, for example, during injection molding of polycarbonate, the hydrophilic laminate is heated and pressurized at 290 ° C. and 200 MPa. At this time, either the fine convex part or the concave part on the surface of the hydrophilic resin layer may be deformed. Examples of the deformation include a decrease in the height of the fine convex portion and a decrease in the depth of the fine concave portion. Although it may be deformed as long as it does not affect the antifogging performance, if it is deformed too much, the contact angle of pure water is increased and the antifogging performance is deteriorated. When the Martens hardness is less than 50 N / mm ² , when the hydrophilic laminate is molded, one of the fine convex portions and concave portions on the surface of the hydrophilic resin layer is excessively deformed, The water contact angle is increased and the antifogging performance is deteriorated, and the hydrophilic resin layer is subjected to surface cleaning during normal use, such as handling and surface cleaning when manufacturing or molding the hydrophilic laminate. In some cases, scratches are likely to occur, and if it exceeds 300 N / mm ² , cracks may occur in the hydrophilic resin layer or the hydrophilic resin layer may be peeled off during molding. When the Martens hardness is within the particularly preferable range, the hydrophilic laminate is variously three-dimensional without deteriorating antifogging performance and without causing defects such as scratches, cracks, and peeling. This is advantageous in that it can be easily formed into a shape.
In addition, after the said hydrophilic laminated body is shape | molded, since the high temperature / high pressure is added to the said hydrophilic resin layer at the injection molding process, the Martens hardness of the said hydrophilic resin layer may increase rather than before a shaping | molding process.
The Martens hardness can be measured by using, for example, PICODETOR HM500 (trade name; manufactured by Fisher Instruments). The load is 1 mN / 20 s, a diamond cone is used as the needle, and the surface angle is 136 °.

There is no restriction | limiting in particular as pencil hardness of the said hydrophilic resin layer, Although it can select suitably according to the objective, B-4H is preferable, HB-4H is more preferable, F-4H is especially preferable. When the pencil hardness is less than B (softer than B), the hydrophilic resin layer is formed on the hydrophilic resin layer by surface cleaning during normal use, such as handling or surface cleaning when manufacturing or molding the hydrophilic laminate. Scratches easily. In addition, when the hydrophilic laminate is molded, any one of the fine convex portions and concave portions on the surface of the hydrophilic resin layer is deformed excessively, and the pure water contact angle is increased and the anti-fogging performance is deteriorated. Sometimes. If the pencil hardness exceeds 4H (harder than 4H), cracks may occur in the hydrophilic resin layer or the hydrophilic resin layer may peel off during molding. When the pencil hardness is within the particularly preferable range, the hydrophilic laminate is variously three-dimensional without deteriorating antifogging performance and without causing defects such as scratches, cracks, and peeling. This is advantageous in that it can be easily formed into a shape.
In addition, after the said hydrophilic laminated body is shape | molded, since the high temperature / high pressure is added to the said hydrophilic resin layer in an injection molding process, the pencil hardness of the said hydrophilic resin layer may increase rather than before a shaping | molding process.
The pencil hardness is measured according to JIS K 5600-5-4.

  There is no restriction | limiting in particular as average thickness of the said hydrophilic resin layer, Although it can select suitably according to the objective, 1 micrometer-100 micrometers are preferable, 1 micrometer-50 micrometers are more preferable, and 1 micrometer-30 micrometers are especially preferable.

<Other members>
Examples of the other members include an anchor layer.

-Anchor layer-
The anchor layer is a layer provided between the resin base material and the hydrophilic resin layer.
By providing the anchor layer, the adhesiveness between the resin substrate and the hydrophilic resin layer can be improved.
The refractive index of the anchor layer is preferably close to the refractive index of the hydrophilic resin layer in order to prevent interference unevenness. Therefore, the refractive index of the anchor layer is preferably within ± 0.10 of the refractive index of the hydrophilic resin layer, and more preferably within ± 0.05. Or it is preferable that the refractive index of the said anchor layer is between the refractive index of the said hydrophilic resin layer and the refractive index of the said resin-made base materials.

  The anchor layer can be formed, for example, by applying an active energy ray curable resin composition. As the active energy ray-curable resin composition, for example, an active energy ray-curable resin composition containing at least urethane (meth) acrylate and a photopolymerization initiator, and further containing other components as necessary. Such as things. Examples of the urethane (meth) acrylate and the photopolymerization initiator include the urethane (meth) acrylate and the photopolymerization initiator exemplified in the description of the hydrophilic resin layer. There is no restriction | limiting in particular as said application | coating method, According to the objective, it can select suitably, For example, wire bar coating, blade coating, spin coating, reverse roll coating, die coating, spray coating, roll coating, gravure coating , Micro gravure coating, lip coating, air knife coating, curtain coating, comma coating method, dipping method and the like.

  There is no restriction | limiting in particular as average thickness of the said anchor layer, Although it can select suitably according to the objective, 0.01 micrometer-10 micrometers are preferable, 0.1 micrometer-5 micrometers are more preferable, 0.3 micrometer-3 micrometers are especially preferable.

  Note that the anchor layer may be provided with a function of reducing reflectance or preventing static electricity.

There is no restriction | limiting in particular as elongation rate of the said hydrophilic laminated body, Although it can select suitably according to the objective, 10% or more is preferable, 10%-200% are more preferable, 40%-150% are especially preferable. preferable. If the elongation is less than 10%, molding may be difficult. When the elongation percentage is within the particularly preferable range, it is advantageous in that the moldability is excellent.
The said elongation rate can be calculated | required with the following method, for example.
The hydrophilic laminate is formed into a strip having a length of 10.5 cm and a width of 2.5 cm, and used as a measurement sample. The tensile elongation of the obtained measurement sample is measured with a tensile tester (Autograph AG-5kNXplus, manufactured by Shimadzu Corporation) (measurement condition: tensile speed = 100 mm / min; distance between chucks = 8 cm). In the measurement of the elongation percentage, the measurement temperature varies depending on the type of the resin base material, and the elongation percentage is measured at a temperature near or above the softening point of the resin base material. Specifically, it is between 10 ° C and 250 ° C. For example, when the resin substrate is a polycarbonate or PC / PMMA laminate, it is preferable to measure at 190 ° C.

  The hydrophilic laminate preferably has a smaller difference in heat shrinkage between the X direction and the Y direction in the plane of the hydrophilic laminate. The X direction and the Y direction of the hydrophilic laminate correspond to, for example, the longitudinal direction and the width direction of the roll when the hydrophilic laminate is in a roll shape. The difference between the heat shrinkage rate in the X direction and the heat shrinkage rate in the Y direction in the hydrophilic laminate is preferably within 5% at the heating temperature used in the heating step during molding. Outside this range, during the molding process, the hydrophilic resin layer may be peeled or cracked, or the characters, patterns, images, etc. printed on the surface of the resin substrate may be deformed or misaligned. This may cause the molding process to be difficult.

  The hydrophilic laminate is particularly suitable for in-mold molding films and insert molding films.

  There is no restriction | limiting in particular as a manufacturing method of the said hydrophilic laminated body, Although it can select suitably according to the objective, The manufacturing method of the hydrophilic laminated body of this invention mentioned later is preferable.

(Method for producing hydrophilic laminate)
The method for producing a hydrophilic laminate of the present invention includes at least an uncured resin layer forming step and a hydrophilic resin layer forming step, and further includes other steps as necessary.
The method for producing the hydrophilic laminate is a method for producing the hydrophilic laminate of the present invention.

<Uncured resin layer forming step>
The uncured resin layer forming step is not particularly limited as long as it is a step of forming an uncured resin layer by applying an active energy ray-curable resin composition on a resin substrate, and is appropriately performed depending on the purpose. You can choose.

There is no restriction | limiting in particular as said resin-made base material, According to the objective, it can select suitably, For example, the said resin-made base material etc. which were illustrated in description of the said hydrophilic laminated body of this invention are mentioned.
The active energy ray curable resin composition is not particularly limited and may be appropriately selected depending on the purpose. For example, the active energy ray curable resin composition exemplified in the description of the hydrophilic resin layer of the hydrophilic laminate of the present invention. An active energy ray-curable resin composition is exemplified.

  The uncured resin layer is formed by applying the active energy ray-curable resin composition on the resin substrate and drying it as necessary. The uncured resin layer may be a solid film or a film having fluidity due to a low molecular weight curable component contained in the active energy ray curable resin composition.

  There is no restriction | limiting in particular as said application | coating method, According to the objective, it can select suitably, For example, wire bar coating, blade coating, spin coating, reverse roll coating, die coating, spray coating, roll coating, gravure coating , Micro gravure coating, lip coating, air knife coating, curtain coating, comma coating method, dipping method and the like.

  The uncured resin layer is not cured because it is not irradiated with active energy rays.

In the uncured resin layer forming step, the active energy ray-curable resin composition may be applied on the anchor layer of the resin base material on which the anchor layer is formed to form the uncured resin layer. Good.
There is no restriction | limiting in particular as said anchor layer, According to the objective, it can select suitably, For example, the said anchor layer etc. which were illustrated in description of the said hydrophilic laminated body of this invention are mentioned.

<Hydrophilic resin layer forming step>
In the hydrophilic resin layer forming step, a transfer master having either a fine convex portion or a concave portion is brought into close contact with the uncured resin layer, and active energy rays are irradiated to the uncured resin layer to which the transfer master is in close contact. If there is a step of forming the hydrophilic resin layer by curing the uncured resin layer and transferring either the fine convex portion or the concave portion, there is no particular limitation, and it is appropriately selected according to the purpose. Can do.

-Transcription master-
The transfer master has either a fine convex part or a concave part.
There is no restriction | limiting in particular as a material of the said transfer original disc, a magnitude | size, and a structure, According to the objective, it can select suitably.
There is no particular limitation on the method for forming any of the fine convex portions and concave portions of the transfer master, and it can be selected as appropriate according to the purpose. However, the transfer using a photoresist having a predetermined pattern shape as a protective film is possible. It is preferably formed by etching the surface of the master. Further, it is preferable to form the transfer master by irradiating the surface of the transfer master with a laser.

-Active energy rays-
The active energy ray is not particularly limited as long as it is an active energy ray that cures the uncured resin layer, and can be appropriately selected according to the purpose. For example, the description of the hydrophilic laminate of the present invention. And the active energy rays exemplified in 1.

  Here, the specific example of the said hydrophilic resin layer formation process is demonstrated using figures.

[First Embodiment]
In the first embodiment, the hydrophilic resin is formed by using a transfer master in which either a fine convex portion or a concave portion is formed by etching the surface of the transfer master using a photoresist having a predetermined pattern shape as a protective film. It is an example of a layer formation process.

  First, the transfer master and its manufacturing method will be described.

[Configuration of the transfer master]
FIG. 3A is a perspective view illustrating an example of a configuration of a roll master that is a transfer master. 3B is an enlarged plan view showing a part of the roll master shown in FIG. 3A. 3C is a cross-sectional view of the track T in FIG. 3B. The roll master 231 is a transfer master for producing a hydrophilic laminate having the above-described configuration, more specifically, a master for forming a plurality of convex portions or concave portions on the surface of the hydrophilic resin layer. . The roll master 231 has, for example, a columnar or cylindrical shape, and the columnar surface or cylindrical surface is a molding surface for molding a plurality of convex portions or concave portions on the surface of the hydrophilic resin layer. For example, a plurality of structures 232 are two-dimensionally arranged on the molding surface. In FIG. 3C, the structure 232 has a concave shape with respect to the molding surface. As a material of the roll master 231, for example, glass can be used, but it is not particularly limited to this material.

  The plurality of structures 232 disposed on the molding surface of the roll master 231 and the plurality of protrusions or recesses disposed on the surface of the hydrophilic resin layer have an inverted uneven relationship. That is, the arrangement, size, shape, arrangement pitch, height or depth, aspect ratio, and the like of the structures 232 of the roll master 231 are the same as the convex portions or concave portions of the hydrophilic resin layer.

[Roll master exposure equipment]
FIG. 4 is a schematic diagram showing an example of the configuration of a roll master exposure apparatus for producing a roll master. This roll master exposure apparatus is configured based on an optical disk recording apparatus.

  The laser light source 241 is a light source for exposing the resist deposited on the surface of the roll master 231 as a recording medium, and oscillates a recording laser beam 234 having a wavelength λ = 266 nm, for example. The laser light 234 emitted from the laser light source 241 travels straight as a parallel beam and enters an electro-optic element (EOM: Electro Optical Modulator) 242. The laser beam 234 that has passed through the electro-optical element 242 is reflected by the mirror 243 and guided to the modulation optical system 245.

  The mirror 243 is composed of a polarization beam splitter and has a function of reflecting one polarization component and transmitting the other polarization component. The polarization component transmitted through the mirror 243 is received by the photodiode 244, and the electro-optic element 242 is controlled based on the received light signal to perform phase modulation of the laser beam 234.

In the modulation optical system 245, the laser beam 234 is collected by an acousto-optic modulator (AOM) 247 made of glass (SiO ₂ ) or the like by a condenser lens 246. The laser beam 234 is intensity-modulated by the acousto-optic element 247 and diverges, and then converted into a parallel beam by the lens 248. The laser beam 234 emitted from the modulation optical system 245 is reflected by the mirror 251 and guided horizontally and parallel on the moving optical table 252.

  The moving optical table 252 includes a beam expander 253 and an objective lens 254. The laser beam 234 guided to the moving optical table 252 is shaped into a desired beam shape by the beam expander 253 and then irradiated to the resist layer on the roll master 231 through the objective lens 254. The roll master 231 is placed on a turntable 256 connected to a spindle motor 255. Then, while rotating the roll master 231 and moving the laser beam 234 in the height direction of the roll master 231, the laser light 234 is intermittently applied to the resist layer formed on the peripheral side surface of the roll master 231. Then, a resist layer exposure step is performed. The formed latent image has a substantially elliptical shape having a major axis in the circumferential direction. The laser beam 234 is moved by moving the moving optical table 252 in the arrow R direction.

  The exposure apparatus includes a control mechanism 257 for forming a latent image corresponding to the two-dimensional pattern of the plurality of convex portions or concave portions described above on the resist layer. The control mechanism 257 includes a formatter 249 and a driver 250. The formatter 249 includes a polarity reversal unit, and this polarity reversal unit controls the irradiation timing of the laser beam 234 on the resist layer. The driver 250 receives the output from the polarity inversion unit and controls the acoustooptic device 247.

  In this roll master exposure apparatus, the polarity inversion formatter signal and the rotation controller are synchronized for each track so that the two-dimensional pattern is spatially linked, and the intensity is modulated by the acousto-optic element 247. A two-dimensional pattern such as a hexagonal lattice pattern can be recorded by patterning with a constant angular velocity (CAV) and an appropriate rotational speed, an appropriate modulation frequency, and an appropriate feed pitch.

[Resist film formation process]
First, as shown in the cross-sectional view of FIG. 5A, a columnar or cylindrical roll master 231 is prepared. The roll master 231 is, for example, a glass master. Next, as shown in the cross-sectional view of FIG. 5B, a resist layer (for example, a photoresist) 233 is formed on the surface of the roll master 231. Examples of the material for the resist layer 233 include organic resists and inorganic resists. Examples of the organic resist include novolak resist and chemically amplified resist. Examples of the inorganic resist include metal compounds.

[Exposure process]
Next, as shown in the cross-sectional view of FIG. 5C, the resist layer 233 formed on the surface of the roll master 231 is irradiated with laser light (exposure beam) 234. Specifically, the roll master 231 is placed on the turntable 256 of the roll master exposure apparatus shown in FIG. 4, the roll master 231 is rotated, and the resist layer 233 is irradiated with a laser beam (exposure beam) 234. . At this time, the laser beam 234 is intermittently irradiated while moving the laser beam 234 in the height direction of the roll master 231 (a direction parallel to the central axis of the columnar or cylindrical roll master 231). Layer 233 is exposed over the entire surface. Thereby, a latent image 235 corresponding to the locus of the laser beam 234 is formed over the entire surface of the resist layer 233.

  For example, the latent image 235 is arranged to form a plurality of rows of tracks T on the surface of the roll master, and is formed with a regular periodic pattern of a predetermined unit cell Uc. The latent image 235 has, for example, a circular shape or an elliptical shape. When the latent image 235 has an elliptical shape, the elliptical shape preferably has a major axis direction in the extending direction of the track T.

[Development process]
Next, for example, while rotating the roll master 231, a developing solution is dropped on the resist layer 233 to develop the resist layer 233. As a result, a plurality of openings are formed in the resist layer 233 as shown in the cross-sectional view of FIG. 5D. When the resist layer 233 is formed of a positive type resist, the exposed portion exposed with the laser beam 234 has a higher dissolution rate in the developer than the non-exposed portion, and as shown in the sectional view of FIG. 5D. A pattern corresponding to the latent image (exposed portion) 235 is formed on the resist layer 233. The pattern of the opening is, for example, a regular periodic pattern of a predetermined unit cell Uc.

[Etching process]
Next, the surface of the roll master 231 is etched using the pattern (resist pattern) of the resist layer 233 formed on the roll master 231 as a mask. Thereby, as shown to sectional drawing of FIG. 5E, the structure (recessed part) 232 which has a cone shape can be obtained. The cone shape is preferably, for example, an elliptical cone shape or an elliptical truncated cone shape having a major axis direction in the extending direction of the track T. As the etching, for example, dry etching or wet etching can be used. At this time, by alternately performing the etching process and the ashing process, for example, a pattern of the cone-shaped structure 232 can be formed. Thus, the intended roll master 231 is obtained.

[Transfer processing]
A resin base material 211 on which an uncured resin layer 236 as shown in the sectional view of FIG. 6A is formed is prepared.
Next, as shown in the sectional view of FIG. 6B, the roll master 231 and the uncured resin layer 236 formed on the resin base material 211 are brought into close contact with each other, and the active energy ray 237 is irradiated to the uncured resin layer 236. Then, the uncured resin layer 236 is cured to transfer any of the fine convex portions and concave portions, thereby obtaining the hydrophilic resin layer 212 in which any one of the fine convex portions and concave portions 212a is formed.
Finally, the obtained hydrophilic resin layer 212 is peeled from the roll master 231 to obtain a hydrophilic laminate (FIG. 6C).
When the resin base material 211 is made of a material that does not transmit active energy rays such as ultraviolet rays, the roll master 231 is made of a material that can transmit active energy rays (for example, quartz). You may make it irradiate an active energy ray with respect to the uncured resin layer 236 from the inside of H.231. The transfer master is not limited to the roll master 231 described above, and a flat master may be used. However, from the viewpoint of improving mass productivity, it is preferable to use the roll master 231 described above as the transfer master.

[Second Embodiment]
In the second embodiment, the hydrophilic resin layer is formed by using a transfer master in which either a fine convex part or a concave part is formed by irradiating the surface of the transfer master with a laser to laser-process the transfer master. It is an example of a process.

  First, the transfer master and its manufacturing method will be described.

[Configuration of the transfer master]
FIG. 7A is a plan view showing an example of the configuration of a plate-shaped master. FIG. 7B is a cross-sectional view taken along the line aa shown in FIG. 7A. FIG. 7C is an enlarged cross-sectional view of a part of FIG. 7B. The plate-shaped master 331 is a master for producing a hydrophilic laminate having the above-described configuration, more specifically, a master for forming a plurality of convex portions or concave portions on the surface of the hydrophilic resin layer. is there. The plate-shaped master 331 has, for example, a surface provided with a fine concavo-convex structure, and the surface is a molding surface for molding a plurality of convex portions or concave portions on the surface of the hydrophilic resin layer. For example, a plurality of structures 332 are provided on the molding surface. The structure 332 illustrated in FIG. 7C has a concave shape with respect to the molding surface. As a material of the plate-shaped master 331, for example, a metal material can be used. As the metal material, for example, Ni, NiP, Cr, Cu, Al, Fe, and alloys thereof can be used. The alloy is preferably stainless steel (SUS). Examples of the stainless steel (SUS) include, but are not limited to, SUS304, SUS420J2, and the like.

  The plurality of structures 332 provided on the molding surface of the plate-shaped master 331 and the plurality of protrusions or recesses provided on the surface of the hydrophilic resin layer have an inverted uneven relationship. That is, the arrangement, size, shape, arrangement pitch, height, depth, and the like of the structures 332 of the plate-shaped master 331 are the same as those of the convex portions or concave portions of the hydrophilic resin layer.

[Configuration of laser processing equipment]
FIG. 8 is a schematic diagram showing an example of the configuration of a laser processing apparatus for producing a plate-shaped master. The laser body 340 is, for example, IFRIT (trade name) manufactured by Cyber Laser Corporation. The wavelength of the laser used for laser processing is, for example, 800 nm. However, the wavelength of the laser used for laser processing may be 400 nm or 266 nm. The repetition frequency is preferably larger in consideration of the processing time and the narrow pitch of the concave portions or convex portions to be formed, and is preferably 1,000 Hz or more. The laser pulse width is preferably shorter, and is preferably about 200 femtoseconds ( ^10-15 seconds) to 1 picosecond ( ^10-12 seconds).

  The laser body 340 emits laser light linearly polarized in the vertical direction. Therefore, in this apparatus, linear polarization or circular polarization in a desired direction is obtained by rotating the polarization direction using a wave plate 341 (for example, a λ / 2 wave plate). Further, in this apparatus, a part of the laser light is extracted using an aperture 342 having a square opening. This is because the intensity distribution of the laser beam is a Gaussian distribution, so that only the center vicinity is used to obtain a laser beam having a uniform in-plane intensity distribution. Further, in this apparatus, the laser beam is focused using two orthogonal cylindrical lenses 343 so that a desired beam size is obtained. When processing the plate-shaped master 331, the linear stage 344 is moved at a constant speed.

  The beam spot of the laser irradiated on the plate-shaped master 331 is preferably rectangular. The beam spot can be shaped by using, for example, an aperture or a cylindrical lens. Further, the intensity distribution of the beam spot is preferably as uniform as possible. This is because it is preferable to make the in-plane distribution such as the depth of the unevenness formed in the mold as uniform as possible. In general, since the size of the beam spot is smaller than the area to be processed, it is necessary to give an uneven shape to all the areas to be processed by scanning the beam.

The master (form) used for forming the surface of the hydrophilic resin layer is, for example, a substrate such as a metal such as SUS, NiP, Cu, Al, Fe, etc., and a pulse width of 1 picosecond ( ^10-12 seconds) or less. It is formed by drawing a pattern using an ultrashort pulse laser, so-called femtosecond laser. The polarization of the laser light may be linearly polarized light, circularly polarized light, or elliptically polarized light. At this time, a pattern having desired irregularities can be formed by appropriately setting the laser wavelength, repetition frequency, pulse width, beam spot shape, polarization, laser intensity applied to the sample, laser scanning speed, and the like.

The parameters that can be changed to obtain the desired shape include the following. The fluence is an energy density (J / cm ² ) per pulse, and is obtained by the following equation.
F = P / (fREPT × S)
S = Lx × Ly
F: fluence P: laser power fREPT: laser repetition frequency S: area at the laser irradiation position Lx × Ly: beam size Note that the number of pulses N is the number of pulses irradiated at one place, and It is calculated by the formula.
N = fREPT × Ly / v
Ly: Beam size in laser scanning direction v: Laser scanning speed

  Further, the material of the plate-shaped master 331 may be changed in order to obtain a desired shape. The shape of laser processing varies depending on the material of the plate-shaped master 331. In addition to using metals such as SUS, NiP, Cu, Al, and Fe, the surface of the master may be coated with a semiconductor material such as DLC (diamond-like carbon). Examples of the method for coating the surface of the master with the semiconductor material include plasma CVD and sputtering. As the semiconductor material to be coated, in addition to DLC, for example, DLC mixed with fluorine (F), titanium nitride, chromium nitride, or the like can be used. The average thickness of the coating obtained by coating may be about 1 μm, for example.

[Laser processing process]
First, as shown in FIG. 9A, a plate-shaped master 331 is prepared. A surface 331A that is a surface to be processed of the plate-like master 331 is in a mirror state, for example. The surface 331A may not be in a mirror state. For example, the surface 331A may have irregularities finer than the transfer pattern, or may be equivalent to the transfer pattern. Rougher irregularities may be formed.

Next, the surface 331A of the plate-shaped master 331 is laser-processed as follows using the laser processing apparatus shown in FIG. First, a pattern is drawn on the surface 331A of the plate-shaped master 331 using an ultrashort pulse laser having a pulse width of 1 picosecond (10 ⁻¹² seconds) or less, so-called femtosecond laser. For example, as shown in FIG. 9B, the surface 331A of the plate-shaped master 331 is irradiated with femtosecond laser light Lf, and the irradiation spot is scanned with respect to the surface 331A.

  At this time, the laser wavelength, the repetition frequency, the pulse width, the beam spot shape, the polarization, the intensity of the laser applied to the surface 331A, the laser scanning speed, etc. are appropriately set, as shown in FIG. A plurality of structures 332 having the structure is formed.

[Transfer processing]
A resin base material 311 having an uncured resin layer 333 as shown in the sectional view of FIG. 10A is prepared.
Next, as shown in the cross-sectional view of FIG. 10B, the plate-shaped master 331 and the uncured resin layer 333 formed on the resin base material 311 are brought into close contact with each other, and the active energy ray 334 is applied to the uncured resin layer 333. Is applied to cure the uncured resin layer 333, transfer any of the fine convex portions and concave portions of the plate-shaped master 331, and form the hydrophilic resin layer 312 on which any of the fine convex portions and concave portions is formed. obtain.
Finally, the obtained hydrophilic resin layer 312 is peeled from the plate-shaped master 331 to obtain a hydrophilic laminate (FIG. 10C).
When the resin base material 311 is made of a material that does not transmit active energy rays such as ultraviolet rays, the plate-shaped master 331 is made of a material that can transmit active energy rays (for example, quartz), You may make it irradiate an active energy ray with respect to the uncured resin layer 333 from the back surface (surface on the opposite side to a shaping | molding surface) of the plate-shaped master 331. FIG.

(Laminated body for antifouling)
The antifouling laminate of the present invention contains at least the hydrophilic laminate of the present invention, and further contains other members as necessary.
The antifouling laminate may be the hydrophilic laminate itself.
The antifouling laminate can prevent hydrophilic stains due to the hydrophilicity of the hydrophilic laminate.

(Goods)
The article of the present invention has the hydrophilic laminate of the present invention on the surface, and further includes other members as necessary.
The article is not particularly limited and can be appropriately selected according to the purpose. Examples thereof include glass windows, refrigerated / frozen showcases, window materials such as automobile windows, bathroom mirrors, automobile side mirrors, and the like. Mirrors, bathroom floors and walls, solar panels, security surveillance cameras, etc.
The article may be glasses, goggles, a helmet, a lens, a microlens array, an automobile headlight cover, a front panel, a side panel, a rear panel, and the like. These are preferably formed by in-mold molding or insert molding.

  The hydrophilic laminate may be formed on a part of the surface of the article or may be formed on the entire surface.

  There is no restriction | limiting in particular as a manufacturing method of the said article | item, Although it can select suitably according to the objective, The manufacturing method of the article | item of this invention mentioned later is preferable.

(Product manufacturing method)
The method for producing an article of the present invention includes at least a heating step, a hydrophilic laminate molding step, and an injection molding step, and further includes other steps as necessary.
The manufacturing method of the article is the manufacturing method of the article of the present invention.

<Heating process>
The heating step is not particularly limited as long as it is a step of heating the hydrophilic laminate, and can be appropriately selected according to the purpose.
The hydrophilic laminate is the hydrophilic laminate of the present invention.

There is no restriction | limiting in particular as said heating, Although it can select suitably according to the objective, It is preferable that it is infrared heating.
There is no restriction | limiting in particular as the temperature of the said heating, Although it can select suitably according to the objective, It is preferable that it is the glass transition temperature vicinity of the said resin-made base materials, or more than a glass transition temperature.
There is no restriction | limiting in particular as time of the said heating, According to the objective, it can select suitably.

<Hydrophilic laminate molding process>
The hydrophilic laminate forming step is not particularly limited as long as it is a step of forming the heated hydrophilic laminate into a desired shape, and can be appropriately selected according to the purpose. The process etc. which make it closely_contact | adhere to a metal mold | die and shape | mold into a desired shape with an air pressure are mentioned.

<Injection molding process>
The injection molding process is not particularly limited as long as it is a process for injecting a molding material onto the resin base material side of the hydrophilic laminate molded into a desired shape and molding the molding material. It can be appropriately selected depending on the case.

  Examples of the molding material include a resin. Examples of the resin include olefin resins, styrene resins, ABS resins (acrylonitrile-butadiene-styrene copolymers), AS resins (acrylonitrile-styrene copolymers), acrylic resins, urethane resins, unsaturated polyesters. Resin, epoxy resin, polyphenylene oxide / polystyrene resin, polycarbonate, polycarbonate modified polyphenylene ether, polyethylene terephthalate, polysulfone, polyphenylene sulfide, polyphenylene oxide, polyether imide, polyimide, liquid crystal polyester, polyallyl heat resistant resin, various composite resins, various modified resins Resin etc. are mentioned.

  The injection method is not particularly limited and may be appropriately selected depending on the purpose. For example, the molten mold is formed on the resin substrate side of the hydrophilic laminate that is in close contact with a predetermined mold. The method of pouring material is mentioned.

  The article manufacturing method is preferably performed using an in-mold molding apparatus, an insert molding apparatus, and an overlay molding apparatus.

Here, an example of a method for manufacturing an article of the present invention will be described with reference to the drawings. This manufacturing method is a manufacturing method using an in-mold molding apparatus.
First, the hydrophilic laminate 500 is heated. Heating is preferably infrared heating.
Subsequently, as shown in FIG. 11A, the heated hydrophilic laminate 500 is disposed at a predetermined position between the first mold 501 and the second mold 502. At this time, it arrange | positions so that the resin-made base materials of the hydrophilic laminated body 500 may face the 1st metal mold | die 501 and a hydrophilic resin layer may face the 2nd metal mold | die 502. FIG. In FIG. 11A, the first mold 501 is a fixed mold, and the second mold 502 is a movable mold.

After the hydrophilic laminate 500 is disposed between the first mold 501 and the second mold 502, the first mold 501 and the second mold 502 are clamped. Subsequently, the hydrophilic laminate 500 is sucked through the suction holes 504 opened in the cavity surface of the second mold 502, and the hydrophilic laminate 500 is mounted on the cavity surface of the second mold 502. By doing so, the cavity surface is shaped with the hydrophilic laminate 500. At this time, the outer periphery of the hydrophilic laminate 500 may be fixed and positioned by a film pressing mechanism (not shown). Thereafter, unnecessary portions of the hydrophilic laminate 500 are trimmed (FIG. 11B).
If the second mold 502 does not have the suction hole 504 and the first mold 501 has a pressurized hole (not shown), the pressurized hole of the first mold 501 can be used to enter the hydrophilic laminate 500. By sending the compressed air, the hydrophilic laminate 500 is mounted on the cavity surface of the second mold 502.

  Subsequently, the molten molding material 506 is injected from the gate 505 of the first mold 501 toward the resin base material of the hydrophilic laminate 500, and the first mold 501 and the second mold 502 are clamped. Then, it is injected into the cavity formed (FIG. 11C). Thereby, the molten molding material 506 is filled in the cavity (FIG. 11D). Further, after the filling of the molten molding material 506 is completed, the molten molding material 506 is cooled to a predetermined temperature and solidified.

Thereafter, the second mold 502 is moved to open the first mold 501 and the second mold 502 (FIG. 11E). By doing so, the article 507 in which the hydrophilic laminate 500 is formed on the surface of the molding material 506 and in-molded into a desired shape is obtained.
Finally, the protruding pin 508 is pushed out from the first mold 501 and the obtained article 507 is taken out.

A manufacturing method in the case of using the overlay molding apparatus is as follows. This is a process of directly decorating the hydrophilic laminate on the surface of the molding material, and an example thereof is a TOM (Three Dimension Overlay Method) method. An example of a method for producing the article of the present invention using the TOM method will be described below.
First, air is sucked with a vacuum pump or the like in both spaces in the apparatus divided by the hydrophilic laminate fixed to the fixed frame, and the spaces are evacuated.
At this time, a molding material that has been injection molded in advance is placed in a space on one side. At the same time, it is heated with an infrared heater until a predetermined temperature at which the hydrophilic laminate is softened. At the timing when the hydrophilic laminate is heated and softened, the hydrophilic laminate is firmly adhered to the three-dimensional shape of the molding material in a vacuum atmosphere by sending air to the side of the apparatus space where there is no molding material. If necessary, compressed air pressing from the side where the atmosphere is sent may be used in combination. After the hydrophilic laminate is in close contact with the molded body, the obtained decorative molded product is removed from the fixed frame. Vacuum forming is usually performed at 80 ° C to 200 ° C, preferably about 110 ° C to 160 ° C.

  In overlay molding, an adhesive layer may be provided on the surface opposite to the hydrophilic surface of the hydrophilic laminate in order to bond the hydrophilic laminate and the molding material. There is no restriction | limiting in particular as said adhesion layer, According to the objective, it can select suitably, For example, an acrylic adhesive, a hot-melt-adhesive etc. are mentioned. There is no restriction | limiting in particular as a formation method of the said adhesion layer, According to the objective, it can select suitably, For example, after forming the said hydrophilic resin layer on the said resin-made base materials, the said of the said resin-made base materials is mentioned. Examples include a method of forming the adhesive layer by applying an adhesive layer coating liquid on the side opposite to the hydrophilic resin layer side. Also, after the adhesive layer coating liquid is applied on the release sheet to form the adhesive layer, the resin base material and the adhesive layer on the release sheet are laminated, and the resin base material is laminated. The adhesive layer may be laminated on top.

(Anti-fouling method)
The antifouling method of the present invention is a method for preventing soiling of the article by laminating the hydrophilic laminate of the present invention on the surface of the article.

The article is not particularly limited and can be appropriately selected according to the purpose. Examples thereof include glass windows, refrigerated / frozen showcases, window materials such as automobile windows, bathroom mirrors, automobile side mirrors, and the like. Mirrors, bathroom floors and walls, solar panels, security surveillance cameras, etc.
The article may be glasses, goggles, a helmet, a lens, a microlens array, an automobile headlight cover, a front panel, a side panel, a rear panel, and the like. These are preferably formed by in-mold molding or insert molding.

  There is no restriction | limiting in particular as a method of laminating | stacking the said hydrophilic laminated body on the surface of the said article | item, According to the objective, it can select suitably, For example, the method of sticking the said hydrophilic laminated body to the surface of the said article | item etc. Is mentioned. The hydrophilic laminate can be laminated on the surface of the article also by the method for producing the article of the present invention.

  Examples of the present invention will be described below, but the present invention is not limited to these examples.

<Average distance of convex part, average distance of concave part, average height of convex part, average depth of concave part, average aspect ratio, and average surface area ratio>
In the following examples, the average distance of the convex portions, the average distance of the concave portions, the average height of the convex portions, the average depth of the concave portions, and the average aspect ratio were determined as follows.
First, the surface of the hydrophilic resin layer having a convex portion or a concave portion is observed with an atomic force microscope (AFM), and the pitch of the convex portion or the concave portion, the height of the convex portion or the concave portion is determined from the cross-sectional profile of the AFM. Sought the depth of. This is repeated at 10 locations randomly selected from the surface of the hydrophilic resin layer, and pitches P1, P2,..., P10 and heights or depths H1, H2,. Asked.
Here, the pitch of the convex portions is a distance between the vertices of the convex portions. The pitch of the recesses is the distance between the deepest portions of the recesses. The height of the convex portion is the height of the convex portion based on the lowest point of the valley between the convex portions. The depth of the recess is the depth of the recess based on the highest point of the peak between the recesses.
Next, these pitches P1, P2,..., P10 and the heights or depths H1, H2,..., H10 are simply averaged (arithmetic average), and the average distance between the convex portions or the concave portions is calculated. (Pm) and the average height of the convex portions or the average depth (Hm) of the concave portions were determined.
An average aspect ratio (Hm / Pm) was determined from the Pm and the Hm.
AFM images were repeatedly obtained at 10 locations randomly selected from the surface of the hydrophilic resin layer having convex portions or concave portions, and surface areas S1, S2,. Next, the ratio (surface area / area) SR1, SR2,..., SR10 of these surface areas S1, S2,..., S10 and the area of each observation region is simply averaged (arithmetic average). The average surface area ratio SRm of the surface of the hydrophilic resin layer was determined.

<Pure water contact angle>
The pure water contact angle was measured by a sliding method using PCA-1 (manufactured by Kyowa Interface Chemical Co., Ltd.) under the following conditions.
-Distilled water was put into a plastic syringe, and a stainless steel needle was attached to the tip thereof and dropped onto the evaluation surface.
・ Drip amount of water: 2μL
・ Measurement temperature: 25 ℃

<Martens hardness>
The Martens hardness of the hydrophilic resin layer was measured using PICODERTOR HM500 (trade name; manufactured by Fisher Instruments). The load was 1 mN / 20 s, a diamond cone was used as the needle, and the surface angle was 136 °.

<Pencil hardness>
The pencil hardness of the hydrophilic resin layer was measured according to JIS K 5600-5-4.

<Elongation>
The elongation rate was determined by the following method.
The hydrophilic laminate was formed into a strip shape having a length of 10.5 cm and a width of 2.5 cm to obtain a measurement sample. The tensile elongation of the obtained measurement sample was measured with a tensile tester (Autograph AG-5kNXplus, manufactured by Shimadzu Corporation) (measurement condition: tensile speed = 100 mm / min; distance between chucks = 8 cm; measurement temperature = 190 ° C.) )did.

<Total light transmittance>
The total light transmittance of the hydrophilic laminate was evaluated using HM-150 (trade name; manufactured by Murakami Color Research Laboratory Co., Ltd.) according to JIS K 7361.

<Haze>
The haze of the hydrophilic laminate was evaluated using HM-150 (trade name; manufactured by Murakami Color Research Laboratory Co., Ltd.) according to JIS K 7136.

<Adhesion>
The adhesiveness of the hydrophilic resin layer was evaluated by a peel test (cross cut (1 mm interval × 100 mass) cellophane tape (manufactured by Nichiban Co., Ltd., CT24)) according to JIS K 5400.

<Heat shrinkage difference>
The difference in the heat shrinkage rate of the hydrophilic laminate was determined by the following method.
First, a square test piece having a size of 100 mm × 100 mm was cut out. At this time, it cut out so that the vertical direction and horizontal direction of this test piece might correspond with the longitudinal direction and width direction of a resin-made base material, respectively. Next, this was heated in an oven at 190 ° C. for 30 minutes. After taking out from the oven and naturally cooling to room temperature, the length in the vertical direction and the horizontal direction were each measured with a ruler. The rate of change from the length before heating (= 100 mm) was calculated for both directions, and the absolute value of the difference was obtained. This was calculated | required with the test piece of N = 10 piece, and those average values were made into the heat contraction rate difference of a hydrophilic laminated body.

Example 1
<Preparation of transfer master (glass roll master) having either fine convex part or concave part>
First, a glass roll master having an outer diameter of 126 mm was prepared, and a resist layer was formed on the surface of the glass roll master as follows. That is, the photoresist was diluted to 1/10 by weight with a thinner, and this diluted resist was applied to the average thickness of about 70 nm on the cylindrical surface of the glass roll master by dipping, thereby forming a resist layer. Next, the glass roll master is transported to the roll master exposure apparatus shown in FIG. 4, and the resist layer is exposed to form a hexagonal lattice pattern between three adjacent tracks while being continuous in one spiral. The latent image was patterned on the resist layer. Specifically, a hexagonal lattice-shaped exposure pattern was formed by irradiating a region where a hexagonal lattice-shaped exposure pattern was to be formed with 0.50 mW / m of laser light.

  Next, the resist layer on the glass roll master was subjected to development treatment, and the exposed resist layer was dissolved and developed. Specifically, an undeveloped glass roll master is placed on a turntable of a developing machine (not shown), and a developer is dropped on the surface of the glass roll master while rotating the entire turntable to develop the resist layer on the surface. did. Thereby, a resist glass master having a resist layer opened in a hexagonal lattice pattern was obtained.

Next, plasma etching was performed in a CHF ₃ gas atmosphere using a roll etching apparatus. As a result, only the hexagonal lattice pattern exposed from the resist layer is etched on the surface of the glass roll master, and the resist layer is used as a mask for the other regions and etching is not performed. Formed on the master. At this time, the etching amount (depth) was adjusted by the etching time. Finally, the resist layer was completely removed by O ₂ ashing to obtain a glass roll master having a concave hexagonal lattice pattern.

<Preparation of hydrophilic laminate>
Next, a hydrophilic laminate was produced by UV imprinting using the roll master obtained as described above. Specifically, it was performed as follows.
DF02U (PMMA / PC laminate) (average thickness 125 μm) manufactured by Mitsubishi Gas Chemical Co., Ltd. was used as the resin base material.
The UV curable resin composition for anchor layer having the following composition was applied on the surface of PMMA of the resin base material so that the average thickness after drying and curing was 0.7 μm.

-UV curable resin composition for anchor layer-
CN985B88 (aliphatic urethane acrylate, manufactured by Sartomer) 15 parts by mass A-9300-1CL (isocyanuric acid group-containing triacrylate) 15 parts by mass (made by Shin-Nakamura Chemical Co., Ltd.)
・ Butyl acetate 68.8 parts by mass ・ Irgacure 184 (manufactured by Ciba Specialty Chemicals) 0.6 part by mass ・ Irgacure 907 (manufactured by Ciba Specialty Chemicals) 0.6 part by mass ・ KP323 (manufactured by Shin-Etsu Chemical Co., Ltd.) 0. 003 parts by mass

After drying, the uncured anchor layer was irradiated with ultraviolet rays at a dose of 500 mJ / cm ² using a mercury lamp to obtain a UV-cured resin substrate with an anchor layer.

An ultraviolet curable resin composition for a hydrophilic resin layer having the following composition was applied on the anchor layer of the resin base material with an anchor layer so that the resulting hydrophilic resin layer had an average thickness of 1.6 μm. The resin base material with an anchor layer coated with the ultraviolet curable resin composition for the hydrophilic resin layer and the roll master obtained as described above are in close contact with each other, using a metal halide lamp, and the resin base material side Then, the hydrophilic resin layer was cured by irradiating with ultraviolet rays at an irradiation amount of 1,500 mJ / cm ² . Thereafter, the hydrophilic resin layer and the roll master were peeled off.

-UV curable resin composition for hydrophilic resin layer-
-A-9300 32 mass parts (ethoxylated isocyanuric acid triacrylate, manufactured by Shin-Nakamura Chemical Co., Ltd.)
-CN985B88 (aliphatic urethane acrylate, manufactured by Sartomer) 32 parts by mass-MPEM-1000 32 parts by mass (methoxypolyethylene glycol 1000 methacrylate, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.)
・ Lucirin TPO (manufactured by BASF) 4 parts by mass

  As described above, a hydrophilic laminate having fine convex portions on the surface of the hydrophilic resin layer was obtained. FIG. 12A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate. A cross-sectional view taken along line aa in FIG. 12A is shown in FIG. 12B.

  About the obtained hydrophilic laminated body, by the above-mentioned method, the average distance (or average distance of a recessed part) (Pm), the average height (or average depth of a recessed part) (Hm), average aspect of a convex part The ratio (Hm / Pm), average surface area ratio (SRm), pure water contact angle, Martens hardness, pencil hardness, elongation, total light transmittance, haze, adhesion, and heat shrinkage difference were measured. The results are shown in Table 2.

Moreover, the following evaluation was performed. The results are shown in Table 3.
<Anti-fogging property>
Anti-fogging properties are as follows. In the environment of 20 ° C., breathe out once from the surface of the hydrophilic resin layer of the hydrophilic laminate in a direction normal to the surface from the surface 5 cm. It was evaluated with.
〔Evaluation criteria〕
○: There was no change in the appearance of the hydrophilic laminate.
X: Appearance changes such as water film formation and white cloudiness were confirmed in the hydrophilic laminate.

<Abrasion resistance>
Scratch resistance of the hydrophilic resin layer is determined by impregnating pure water into a wiping cloth (KB Selen Co., Ltd., savina MX), placing it on the surface of the hydrophilic resin layer, and 1,000 reciprocations at a load of 75 gf / 13 mmφ. After sliding (sliding stroke: 3 cm, sliding frequency: 60 Hz), the following evaluation criteria were used.
〔Evaluation criteria〕
○: No change in appearance and antifogging property.
(Triangle | delta): Although the external appearance did not change, anti-fogging property deteriorated. Or although anti-fogging property did not deteriorate, there were changes, such as a damage | wound and cloudiness, in the external appearance.
X: There were changes such as scratches and cloudiness in the appearance, and the antifogging property was deteriorated.

<Interference unevenness>
First, the double-sided pressure-sensitive adhesive sheet (manufactured by Nitto Denko Corporation) is placed on a black acrylic plate (Mitsubishi Rayon Co., Ltd., trade name: acrylite) so that the evaluation surface (hydrophilic resin layer surface) is on the hydrophilic laminate. The product was pasted using a product name: LUCIACS CS9621T). Next, the evaluation surface was observed under a white fluorescent lamp and evaluated according to the following evaluation criteria.
〔Evaluation criteria〕
○: The evaluation surface was black and interference unevenness could not be confirmed.
Δ: The evaluation surface was slightly colored and interference unevenness was slightly confirmed.
X: The evaluation surface was colored green or red, and interference unevenness was confirmed.

<Molding process>
In-mold molding was performed by the method shown in FIGS. 11A to 11F, and the pure water contact angle, antifogging property, and Martens hardness of the hydrophilic resin layer after molding were evaluated by the above-described evaluation methods. Further, the appearance of the molded product was observed, and the presence or absence of scratches, cracks, and peeling of the hydrophilic resin layer was evaluated.
The heating (infrared heating) temperature in the heating step for heating the hydrophilic laminate was 190 ° C., and polycarbonate was used as the molding material. In in-mold molding, the elongation percentage of the portion where the hydrophilic laminate was most elongated was 40%. The pure water contact angle and antifogging property were evaluated at a site where the hydrophilic laminate had 10% elongation.

(Example 2)
In Example 1, a hydrophilic laminate was produced in the same manner as in Example 1 except that the etching time for producing the glass roll master was changed.
FIG. 13A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate. A cross-sectional view taken along line aa in FIG. 13A is shown in FIG. 13B.
About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

(Example 3)
In Example 2, a hydrophilic laminate was produced in the same manner as in Example 2 except that the exposure pattern for producing the glass roll master was reversed.
FIG. 14A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate. A cross-sectional view taken along line aa in FIG. 14A is shown in FIG. 14B.
About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

Example 4
In Example 1, a hydrophilic laminate was produced in the same manner as in Example 1 except that the etching time for producing the glass roll master was changed.
FIG. 15A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate. A cross-sectional view taken along line aa in FIG. 15A is shown in FIG. 15B.
About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

(Example 5)
In Example 3, a hydrophilic laminate was produced in the same manner as in Example 3 except that the etching time for producing the glass roll master was changed.
FIG. 16A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate. A cross-sectional view taken along line aa in FIG. 16A is shown in FIG. 16B.
About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

(Example 6)
<Preparation of transfer master (plate-like master) having either fine convex part or concave part>
As the laser processing apparatus, the apparatus shown in FIG. 8 was used. As the laser body 340, IFRIT (trade name) manufactured by Cyber Laser Co., Ltd. was used. The laser wavelength was 800 nm, the repetition frequency was 1,000 Hz, and the pulse width was 220 fs.
First, a master was prepared by coating DLC (diamond-like carbon) on the surface of a plate-like substrate (SUS) by a sputtering method. Next, fine concave portions were formed on the surface of the DLC film of the master using the laser processing apparatus. At this time, laser processing was performed under the laser processing conditions shown in Table 1. Thus, a plate-shaped master for shape transfer was obtained. Note that the size of the master was a rectangular shape of 2 cm × 2 cm.

<Preparation of hydrophilic laminate>
Next, a hydrophilic laminate was produced by UV imprinting using the plate-shaped master obtained as described above. Specifically, it was performed as follows.
In the production of the hydrophilic laminate of Example 1, a hydrophilic laminate was produced in the same manner as in Example 1 except that the roll master was replaced with the plate-like master obtained as described above.
FIG. 17A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate. FIG. 17B shows a cross-sectional view taken along the line aa in FIG. 17A.
About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

(Examples 7 to 9)
In Example 6, a hydrophilic laminate was produced in the same manner as in Example 6 except that the conditions for producing the plate-shaped master were changed to the conditions shown in Table 1.
FIG. 18A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate of Example 7. A cross-sectional view taken along the line aa in FIG. 18A is shown in FIG. 18B.
FIG. 19A shows an AFM image of the surface of the hydrophilic resin layer of the obtained hydrophilic laminate of Example 8. A cross-sectional view taken along the line aa in FIG. 19A is shown in FIG. 19B.
FIG. 20A shows an AFM image of the surface of the hydrophilic resin layer of the hydrophilic laminate obtained in Example 9. A cross-sectional view taken along line aa in FIG. 20A is shown in FIG. 20B.
About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

(Example 10)
In Example 1, a hydrophilic laminate was produced in the same manner as in Example 1 except that the UV curable resin composition for anchor layer and the UV curable resin composition for hydrophilic resin layer were changed to the following compositions. did.

-UV curable resin composition for anchor layer-
・ 8BR-500 45 parts by mass (urethane acrylate polymer, Taisei Fine Chemical Co., Ltd.)
・ UV-7550 (urethane acrylate, manufactured by Nippon Gosei Kogyo Co., Ltd.) 15 mass parts ・ Butyl acetate 38.8 mass parts ・ Irgacure 184 (produced by Ciba Specialty Chemicals) 0.6 mass part ・ Irgacure 907 (produced by Ciba Specialty Chemicals Inc.) ) 0.6 parts by mass · KP323 (manufactured by Shin-Etsu Chemical Co., Ltd.) 0.003 parts by mass

-UV curable resin composition for hydrophilic resin layer-
-A-600 43 parts by mass (polyethylene glycol diacrylate, manufactured by Shin-Nakamura Chemical Co., Ltd.)
-M-215 (isocyanuric acid diacrylate, manufactured by Toagosei Co., Ltd.) 43 parts by mass-Light ester THF (1000) 10 parts by mass (THF-modified methacrylate, manufactured by Kyoeisha Chemical Co., Ltd.)
・ Lucirin TPO (manufactured by BASF) 4 parts by mass

  Finally, “Mold Fit 50 (acrylic pressure-sensitive adhesive)” manufactured by Nichiei Kako Co., Ltd. was laminated on the side of the resin base material on which the hydrophilic resin layer was not formed to form an adhesive layer.

  About the produced hydrophilic laminated body, evaluation similar to Example 1 was performed. The results are shown in Tables 2 and 3.

<Molding process>
TOM molding (overlay molding) was performed, and the pure water contact angle, antifogging property, and Martens hardness of the hydrophilic resin layer after molding were evaluated by the above evaluation methods. Further, the appearance of the molded product was observed, and the presence or absence of scratches, cracks, and peeling of the hydrophilic resin layer was evaluated.
The heating (infrared heating) temperature in the heating step for heating the hydrophilic laminate was 150 ° C., a polycarbonate 8-curve lens was used as the molding material, and the hydrophilic laminate was affixed to the concave portion of the lens. In overlay molding, the elongation percentage of the portion where the hydrophilic laminate was most elongated was 75%. The pure water contact angle and anti-fogging property were evaluated at a site where the hydrophilic laminate had 75% elongation. The results are shown in Table 3.

(Example 11)
In Example 10, a hydrophilic laminate was produced in the same manner as in Example 10 except that the etching time for producing the glass roll master was changed. Evaluation similar to Example 10 was performed about the produced hydrophilic laminated body. The results are shown in Tables 2 and 3.

(Example 12)
A hydrophilic laminate was produced in the same manner as in Example 10, except that the UV curable resin composition for anchor layer and the UV curable resin composition for hydrophilic resin layer were changed to the following compositions in Example 10. did. Evaluation similar to Example 10 was performed about the produced hydrophilic laminated body. The results are shown in Tables 2 and 3.

-UV curable resin composition for anchor layer-
・ 8BR-500 45 parts by mass (urethane acrylate polymer, Taisei Fine Chemical Co., Ltd.)
・ UV-7550 (urethane acrylate, manufactured by Nihon Gosei Co., Ltd.) 15 mass parts ・ Butyl acetate 38.8 mass parts ・ Irgacure 184 (manufactured by Ciba Specialty Chemicals) 0.6 mass part ・ Irgacure 907 (manufactured by Ciba Specialty Chemicals) 0.6 parts by mass-KP323 (manufactured by Shin-Etsu Chemical Co., Ltd.) 0.003 parts by mass

-UV curable resin composition for hydrophilic resin layer-
A-600 48 parts by mass (polyethylene glycol diacrylate, manufactured by Shin-Nakamura Chemical Co., Ltd.)
-M-215 (isocyanuric acid diacrylate, manufactured by Toagosei Co., Ltd.) 28 parts by mass-Light ester THF (1000) 20 parts by mass (THF-modified methacrylate, manufactured by Kyoeisha Chemical Co., Ltd.)
・ Lucirin TPO (manufactured by BASF) 4 parts by mass

(Example 13)
In Example 12, a hydrophilic laminate was produced in the same manner as in Example 12 except that the etching time for producing the glass roll master was changed. Evaluation similar to Example 10 was performed about the produced hydrophilic laminated body. The results are shown in Tables 2 and 3.

(Example 14)
In Example 10, the hydrophilic laminated body was produced like Example 10 except having changed the ultraviolet curable resin composition for hydrophilic resin layers into the following composition. Evaluation similar to Example 10 was performed about the produced hydrophilic laminated body. The results are shown in Tables 2 and 3.

-UV curable resin composition for hydrophilic resin layer-
・ A-600 33 parts by mass (polyethylene glycol diacrylate, manufactured by Shin-Nakamura Chemical Co., Ltd.)
-M-215 (isocyanuric acid diacrylate, manufactured by Toagosei Co., Ltd.) 43 parts by mass-Light ester THF (1000) 20 parts by mass (THF-modified methacrylate, manufactured by Kyoeisha Chemical Co., Ltd.)
・ Lucirin TPO (manufactured by BASF) 4 parts by mass

(Example 15)
In Example 10, the hydrophilic laminated body was produced like Example 10 except having changed the ultraviolet curable resin composition for hydrophilic resin layers into the following composition. Evaluation similar to Example 10 was performed about the produced hydrophilic laminated body. The results are shown in Tables 2 and 3.

-UV curable resin composition for hydrophilic resin layer-
・ A-600 23 parts by mass (polyethylene glycol diacrylate, manufactured by Shin-Nakamura Chemical Co., Ltd.)
-M-215 (isocyanuric acid diacrylate, manufactured by Toagosei Co., Ltd.) 43 parts by mass-Light ester THF (1000) 30 parts by mass (THF-modified methacrylate, manufactured by Kyoeisha Chemical Co., Ltd.)
・ Lucirin TPO (manufactured by BASF) 4 parts by mass

(Comparative Example 1)
In Example 1, a laminate was obtained in the same manner as in Example 1 except that the roll master was not adhered to the anchor-coated resin base material coated with the ultraviolet curable resin composition for the hydrophilic resin layer. It was.

The hydrophilic laminates of Examples 1 to 15 had a pure water contact angle of less than 40 ° and were excellent in antifogging properties. Moreover, it was excellent in scratch resistance and interference unevenness. Moreover, compared with the comparative example 1 which does not have either a fine convex part and a recessed part, the total light transmittance was high. This is due to the antireflection effect of either the fine convex portion or the concave portion. Actually, for example, when the hydrophilic laminate of Example 4 was observed obliquely under a white fluorescent lamp, a slight blue diffracted light was confirmed.
The elongation percentages of the hydrophilic laminates of Examples 1 to 15 were 10% or more and were excellent in molding processability. The Martens hardness of the hydrophilic resin layer before molding processing was 50 N / mm ² or more, and was excellent in antifogging properties and appearance after molding processing. When the surface of the hydrophilic resin layer after the molding process was observed with an atomic force microscope (AFM), the average distance between the convex parts or the concave parts was not changed compared with that before the molding process, and the average height of the convex parts was not changed. Or the average depth of the recesses is about 10% lower or shallower than before the molding process, the average aspect ratio is about 10% smaller than before the molding process, and the average surface area ratio is compared with that before the molding process. About 5% smaller. The deformation of the fine convex part or the concave part on the surface of the hydrophilic resin layer by the molding process was in a range not affecting the antifogging performance.
Further, the Martens hardness of the hydrophilic resin layer was the same before and after the molding process.

  On the other hand, the laminate of Comparative Example 1 that does not have any one of the fine convex part and the concave part has a pure water contact angle after the molding process even though the resin composition having the same composition is used for the outermost surface layer. It was 41 ° and the antifogging property was insufficient.

  The hydrophilic laminate of the present invention includes glass windows, refrigerated / frozen showcases, window materials for automobile windows, mirrors in bathrooms, mirrors such as automobile side mirrors, bathroom floors and walls, solar panel surfaces, crime prevention. It can be attached to a surveillance camera or the like. In addition, since the hydrophilic laminate of the present invention is easy to be molded, glasses, goggles, helmets, lenses, microlens arrays, automobile headlight covers, fronts are used by using in-mold molding and insert molding. It can be used for panels, side panels, rear panels and the like.

211 resinous base material 212 hydrophilic resin layer 231 roll master 232 structure 236 uncured resin layer 237 active energy ray 311 resin base material 312 hydrophilic resin layer 331 plate master 332 structure 333 uncured resin layer 334 active Energy rays

Claims (9)

A method for producing a hydrophilic laminate,
An anchor layer forming step of applying an ultraviolet curable resin composition containing at least urethane acrylate on a resin base material and irradiating ultraviolet rays to form an anchor layer which is a cured resin layer;
An uncured resin layer forming step of applying an active energy ray-curable resin composition on the anchor layer to form an uncured resin layer;
Adhering a transfer master having either a fine convex part or a concave to the uncured resin layer, irradiating the uncured resin layer to which the transfer master is in contact with an active energy ray to cure the uncured resin layer A hydrophilic resin layer forming step of forming a hydrophilic resin layer by transferring any of the fine convex portions and concave portions,
The hydrophilic resin layer has either a fine convex part or a concave part on the surface,
The pure water contact angle on the surface of the hydrophilic resin layer is less than 40 °,
The method for producing a hydrophilic laminate, wherein the elongation percentage of the hydrophilic laminate is 10% or more and 75% or less. The method for producing a hydrophilic laminate according to claim 1, wherein the difference between the heat shrinkage in the X direction and the heat shrinkage in the Y direction within the surface of the hydrophilic laminate is within 5%. The Martens hardness of the hydrophilic resin layer is 50 N / mm ² ~ 300N / mm ² The method for producing a hydrophilic laminate according to any one of claims 1 to 2. The manufacturing method of the hydrophilic laminated body in any one of Claim 1 to 3 in which a hydrophilic resin layer contains the hardened | cured material of the active energy ray curable resin composition containing polyethyleneglycol (meth) acrylate. 5. The method according to claim 1, wherein any one of the fine convex portion and the concave portion of the transfer master is formed by etching the surface of the transfer master using a photoresist having a predetermined pattern shape as a protective film. A method for producing a hydrophilic laminate. 5. The hydrophilicity according to claim 1, wherein any one of the fine convex portion and the concave portion of the transfer master is formed by irradiating the surface of the transfer master with laser to process the transfer master. A manufacturing method of a layered product. A heating step of heating the hydrophilic laminate produced by the method for producing a hydrophilic laminate according to any one of claims 1 to 6;
A hydrophilic laminate forming step of forming the heated hydrophilic laminate into a desired shape;
A method for producing an article, comprising: an injection molding step of injecting a molding material onto a resin substrate side of the hydrophilic laminate formed into a desired shape and molding the molding material. The method for manufacturing an article according to claim 7, wherein the heating in the heating step is performed by infrared heating. An antifouling method comprising preventing the article from being soiled by laminating the hydrophilic laminate produced by the method for producing a hydrophilic laminate according to any one of claims 1 to 6 on the surface of the article.