JP6256021B2 - Active energy ray-curable composition for forming optical film or sheet and optical film or sheet - Google Patents

Description

The present invention relates to an active energy ray-curable composition used for forming an optical film or sheet, and an optical film or sheet obtained by curing the composition, and belongs to these technical fields.
In the following, for the sake of convenience, unless otherwise specified, “optical film or sheet” is described as “optical film”. Further, acrylate or methacrylate is represented as (meth) acrylate.

In recent years, a liquid crystal display device integrated with a touch panel has been widely applied to mobile devices such as smartphones, tablet terminals, and car navigation systems.
Conventionally, as a transparent conductive thin film of a touch panel, a conductive glass in which a thin film of indium tin oxide (hereinafter referred to as ITO) is formed on a glass substrate is well known. However, there is a problem that the transparent conductive film having a glass substrate is inferior in flexibility and workability.

If these problems are not preferred depending on the application, polyethylene terephthalate film (glass transition temperature) is advantageous in that it is superior in flexibility and workability, in addition to glass substrates, in addition to excellent impact resistance and light weight. A transparent conductive film having a base material of about 120 ° C. (hereinafter referred to as “Tg”) is used.
On the other hand, a touch panel integrated display device is often used outdoors or in a vehicle, and the display surface is reflected to reduce visibility, so that the viewer can suppress the reflection on the touch panel surface. I often wear sunglasses. However, the touch panel surface screen viewed through polarized sunglasses has a problem that rainbow-colored unevenness occurs due to a large in-plane retardation value of the polyethylene terephthalate film (about 3,000 nm when the thickness is 100 μm).

As a transparent conductive film that solves the problem of uneven rainbow color, a transparent conductive film based on a cycloolefin polymer film having a low in-plane retardation value (10 nm or less when the thickness is 100 μm) is partially put into practical use. ing.
However, the transparent conductive film prevents adhesion of the hard coat layer used for preventing scratches when transported by a roll-to-roll method, and prevents the ITO electrode pattern from appearing on the capacitive touch panel. The adhesiveness of the index matching layer used for visualization was insufficient.

  In addition, a polarizing plate with a λ / 4 plate used for a polarizing plate constituting a liquid crystal display device or an organic EL display device is required to be thin and light and high durability. In particular, a polarizer protective film has high moisture resistance. Thermal properties are required.

  In order to solve such problems, an in-plane retardation value is low, and since it has excellent adhesion and heat resistance with an acrylic hard coat layer, an acrylic three-dimensional crosslinked film as a base material for a transparent conductive film Is being considered. Among them, it is preferable to use a radical active energy ray-curable composition because curing proceeds in a short time and productivity is high, and since it exhibits excellent mechanical properties, two or more (meth) acryloyl groups are used. A composition containing a compound having the following [hereinafter referred to as polyfunctional (meth) acrylate] or urethane (meth) acrylate is often used.

  Furthermore, if the water absorption rate of the plastic film is too large, it takes time to create a vacuum state when forming the ITO film, which increases the cost. Therefore, a reduction in water absorption rate is required, and also for mass productivity and cost reduction. In addition, bending resistance that can be stably conveyed by a roll-to-roll method has been demanded.

  Patent Document 1 discloses a transparent resin molded article having a Tg of 150 ° C. or higher and a saturated water absorption of 3% or less, obtained by photocuring a photocurable composition containing a polyfunctional (meth) acrylate. . However, since the composition described in the same document does not have a solvent drying step and there is no foaming of the cured product, the composition starting from bubbles does not occur, but in the composition mainly composed of polyfunctional (meth) acrylate, Since the cured film is inferior in bending resistance, it cannot be stably conveyed by the roll-to-roll method, so it is limited to use on a single wafer, and the metal oxide adhesion decreases when the saturated water absorption is 2% or more. there were.

  Patent Document 2 discloses a plastic member having a Tg of 200 ° C. or more and a water absorption of 1% or less, obtained by photocuring a photocurable composition containing a bismethacrylate having an alicyclic skeleton and a mercapto compound. Yes. However, although the member described in the same document gives a moderate toughness to the cured product by blending a mercapto compound, it is not sufficiently flexible and cannot be stably conveyed by a roll-to-roll method. There is a problem that the pot life of the composition is shortened and the stability of the composition is lowered.

  In Patent Document 3, a compound having urethane (meth) acrylate and alicyclic skeleton and one (meth) acryloyl group, which is a reaction product of polycarbonate diol or polyester diol, organic diisocyanate and hydroxyl group-containing (meth) acrylate. An electron beam curable composition containing a cured product having a water absorption of 1.0% or less is disclosed. However, although the cured product described in the same document has sufficient bending resistance, it can be stably conveyed by a roll-to-roll method, but when used as a substrate for a transparent conductive film, the Tg of the cured product. However, there is a problem in appearance that wrinkles occur because the temperature is lower than the vacuum film formation temperature of metal oxide or the like.

  As described above, there is no appearance defect such as bubbles, low water absorption, Tg that does not cause appearance defects due to vacuum film formation of metal oxides, etc., and bending resistance capable of roll-to-roll conveyance can be satisfied at the same time. No active energy ray-curable composition has been found so far.

JP 2008-85323 A JP 2002-161113 A JP 2012-46566 A

  An object of the present invention is to provide an active energy ray-curable composition for forming an optical film, in which the cured product is excellent in heat resistance and flex resistance, has a low in-plane retardation value, and does not have poor appearance such as bubbles, and the composition It is to provide an optical film obtained from the above.

  As a result of intensive studies in order to solve the above problems, the present inventors have obtained a (meth) acrylate polymer having a (meth) acryloyl group in the side chain and a compound having two or more (meth) acryloyl groups. It has been found that the active energy ray-curable composition is effective.

According to the composition of the present invention, it is possible to provide an optical film in which the cured product is excellent in heat resistance and flex resistance, has a low in-plane retardation value, and does not have poor appearance such as bubbles.
As a result, particularly when the optical film of the present invention is used as a base material for a transparent conductive film, the heat resistance is excellent, so there is no appearance defect due to vacuum film formation of a metal oxide or the like, and the bending resistance is excellent. Therefore, roll-to-roll conveyance is possible.

FIG. 1 shows an example of production of an optical film using the composition of the present invention. FIG. 2 shows an example of production of an optical film using the composition of the present invention.

The present invention is a composition comprising the following component (A) or / and component (B) and component (C), based on the total amount of component (A), component (B) and component (C) , (A) component 50 to 95% by weight, (B) component 50 to 95% by weight [provided that when (A) and (B) components are used in combination, the total amount is 50 to 95% by weight) and (C) Including 5 to 50% by weight of component,
The Tg (glass transition temperature) of the cured product is 120 ° C. or higher,
The present invention relates to an active energy ray-curable composition for forming an optical film or sheet in which the water absorption of the cured product is 2.0% or less.
Component (A): (meth) acrylate polymer (a1) [hereinafter referred to as “polymer (a1)”] having a functional group capable of reacting with a carboxyl group or a hydroxyl group in the side chain, a carboxyl group or a hydroxyl group and ( A compound having a (meth) acryloyl group and having a (meth) acryloyl group in the side chain which is a reaction product with the compound (a2) having a number average molecular weight of 180 or more (hereinafter referred to as “compound (a2)”) Acrylate polymer (B) component: (meth) acrylate polymer (b1) having a carboxyl group or a hydroxyl group in the side chain obtained by copolymerizing compound (a2) and a monomer copolymerizable therewith A (meth) acryloyl group-containing (meth) acrylic group is present in the side chain which is a reaction product of the compound (b2) having a carboxyl group or a functional group capable of reacting with a hydroxyl group and a (meth) acryloyl group. Rate-based polymer component (C): (A) and (B) a compound having two or more (meth) acryloyl group other than the component will be described in detail the present invention. In the present specification, a crosslinked product and a cured product obtained by irradiating the composition with active energy rays are collectively referred to as a “cured product”.

1. Component (A) The component (A) is a (meth) acrylate polymer having a (meth) acryloyl group in the side chain which is a reaction product of the polymer (a1) and the compound (a2).
In the present invention, the “(meth) acrylate polymer” means a polymer having (meth) acrylate as a main component as a constituent monomer unit.
Hereinafter, the reaction of the polymer (a1), the compound (a2) and the polymer (a1) with the compound (a2) will be described.

1-1. Polymer (a1)
The polymer (a1) is a (meth) acrylate polymer having a functional group capable of reacting with a carboxyl group or a hydroxyl group in the side chain.
Examples of the functional group capable of reacting with a carboxyl group include an epoxy group and an isocyanate group.
Examples of the functional group capable of reacting with a hydroxyl group include an isocyanate group.
As the polymer (a1), a (meth) acrylate polymer having an epoxy group in the side chain and a (meth) acrylate polymer having an isocyanate group in the side chain are preferable.

  As the polymer (a1), a compound having a functional group capable of reacting with a carboxyl group or a hydroxyl group and an ethylenically unsaturated group [hereinafter referred to as “monomer (a11)”], the monomer (a11), A copolymer with a copolymerizable ethylenically unsaturated group-containing compound (hereinafter referred to as “monomer (a12)”) is preferred.

As the monomer (a11), a compound having an epoxy group and an ethylenically unsaturated group (hereinafter referred to as “epoxy unsaturated compound”) and a compound having an isocyanate group and an ethylenically unsaturated group (hereinafter referred to as “isocyanate”). Can be mentioned.) ”.
Examples of the epoxy unsaturated compound include glycidyl (meth) acrylate, 3,4-epoxycyclohexyl (meth) acrylate, and 4-hydroxybutyl (meth) acrylate glycidyl ether.
Examples of the isocyanate-based unsaturated compound include 2-isocyanate ethyl (meth) acrylate, monoadducts of isophorone diisocyanate and 2-hydroxyethyl acrylate, and the like.
As the monomer (a11), an epoxy-based unsaturated group compound is preferable from the viewpoint that the cured composition is excellent in optical characteristics.

The monomer (a12) is not particularly limited as long as it is a compound that can be copolymerized with the monomer (a11) and has an ethylenically unsaturated group, but can be copolymerized with the monomer (a11). A compound having a (meth) acryloyl group is preferred because of its superiority.
As a compound having a (meth) acryloyl group, methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, t-butyl (meth) acrylate, isobornyl (meth) acrylate, cyclohexyl ( (Meth) acrylates such as (meth) acrylate, dicyclopentanyl (meth) acrylate, dicyclopentenyl (meth) acrylate, glycidyl (meth) acrylate;
N- (meth) acryloylmorpholine;
Acrylamides such as (meth) acrylamide, N-methylolacrylamide, N, N-dimethyl (meth) acrylamide, N, N-diethyl (meth) acrylamide and N, N-dimethylaminopropyl (meth) acrylamide; and (meth) Examples include acrylonitrile.

  Among these compounds, the monomer (a12) is preferably methyl (meth) acrylate, more preferably methyl methacrylate, from the viewpoint of excellent optical properties of the obtained component (A). In other unsaturated compounds, the proportion of methyl methacrylate is preferably 50% by weight or more.

  The copolymerization ratio of the monomer (a11) and the monomer (a12) is preferably monomer (a11): monomer (a12) = 1-50: 99-50 (weight ratio). . The composition containing the component (A) obtained from the copolymer (a1) having this copolymerization ratio has excellent mechanical properties, particularly elongation at break, of the cured product.

The method for producing the copolymer of the monomer (a11) and the monomer (a12) is not particularly limited, and using the above-described compounds, suspension polymerization, emulsion polymerization, bulk polymerization, solution polymerization, etc. These known methods can be used.
Among these, the solution polymerization method is preferable because the polymer can be easily produced and does not contain extra impurities such as an emulsifier.

  In the case of producing by a solution polymerization method, the raw material monomer to be used is dissolved in an organic solvent, a thermal polymerization initiator is added, and the mixture is heated and stirred. When synthesizing by radical polymerization by a solution polymerization method, the raw material monomer to be used is dissolved in an organic solvent, a thermal radical polymerization initiator is added, and the mixture is heated and stirred. Further, a chain transfer agent can be used to adjust the molecular weight of the polymer, if necessary.

  Organic solvents used in the solution polymerization method include ketones such as acetone, methyl ethyl ketone and methyl isobutyl ketone; esters such as ethyl acetate and butyl acetate; ethers such as propylene glycol monomethyl ether; aromatic carbonization such as toluene and xylene. Hydrogen; and aliphatic hydrocarbons such as hexane, heptane and mineral spirit.

As thermal polymerization initiators, azo initiators such as azobisisobutyronitrile, azobisisovaleronitrile, azobiscyclohexanecarbonitrile, and azobiscyanovaleric acid;
Organic peroxides such as t-butyl peroxypivalate, t-hexyl peroxypivalate, dilauroyl peroxide, di (2-ethylhexyl) peroxydicarbonate, di-t-butyl peroxide and dicumyl peroxide And hydrogen peroxide-iron (II) salt, peroxodisulfate-sodium hydrogen sulfite, cumene hydroperoxide-iron (II) salt, and the like.
What is necessary is just to set the usage-amount of a thermal-polymerization initiator suitably according to the target molecular weight. The use ratio of the thermal polymerization initiator is preferably 0.1 to 10 parts by weight with respect to a total of 100 parts by weight of all monomers used.

  As a weight average molecular weight (hereinafter referred to as “Mw”) of the polymer (a1), in each case, a molecular weight measured by gel permeation chromatography (hereinafter referred to as “GPC”) is expressed as polystyrene-converted value. 000-100,000 are preferable, More preferably, it is 3,000-80,000, More preferably, it is 4,000-50,000.

1-2. Compound (a2)
The compound (a2) is a compound having a carboxyl group or a hydroxyl group and a (meth) acryloyl group and having a number average molecular weight of 180 or more.
In the present invention, the number average molecular weight of the compound (a2) (hereinafter referred to as “P-Mn”) means the number average molecular weight based on the acid value or hydroxyl value.
In the case of a compound having a carboxyl group and a (meth) acryloyl group, it means a value determined according to the following formula.

  In the case of a compound having a hydroxyl group and a (meth) acryloyl group, it means a value determined according to the following formula.

  In the case of a compound having a carboxyl group or a hydroxyl group and a (meth) acryloyl group and having a P-Mn of less than 180, the cured product of the composition containing the resulting polymer becomes brittle. As P-Mn of a compound (a2), 180-1,000 are preferable.

  Specific examples of the compound having a carboxyl group in the compound (a2) [hereinafter referred to as “carboxyl group-containing (meth) acrylic compound”] include caprolactone adduct of (meth) acrylic acid and hydroxyalkyl (meth) acrylate. Examples include acid anhydride adducts.

The caprolactone adduct of (meth) acrylic acid is a compound represented by the following formula (1).
CH ₂ ═C (R ¹ ) CO [O (CH ₂ ) ₅ CO] _n OH (1)
[However, in the above formula (1), R ¹ is a hydrogen atom or a methyl radical, n is a number from 1 to 10. ]

In the acid anhydride adduct of hydroxyalkyl (meth) acrylate, examples of hydroxyalkyl (meth) acrylate include hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, hydroxybutyl (meth) acrylate, and the like. Examples of the anhydride include phthalic anhydride, hexahydrophthalic anhydride, and succinic anhydride.
Specific examples of the hydroxyalkyl (meth) acrylate acid anhydride adduct include hydroxyethyl (meth) acrylate phthalic anhydride adduct and hydroxyethyl (meth) acrylate succinic anhydride adduct.

  Carboxyl group-containing (meth) acrylic compounds are commercially available, ω-carboxypolycaprolactone monoacrylate [Aronix M-5300 manufactured by Toagosei Co., Ltd.] and hydroxyethyl acrylate phthalic anhydride adduct [manufactured by Toagosei Co., Ltd. Aronix M-5400] and the like.

Among these compounds, the carboxyl group-containing (meth) acrylic compound is preferably a caprolactone adduct of (meth) acrylic acid in that the cured product of the composition has excellent mechanical properties, particularly bending resistance.
As n showing the preferable average addition number of the caprolactone in the said Formula (1), 1 or more and 3 or less are preferable. When the value of n is 1 or more, excellent mechanical properties are exhibited, and when the value of n is 3 or less, excellent optical properties (low photoelasticity) are exhibited.

  Specific examples of the compound having a hydroxyl group in the compound (a2) (hereinafter referred to as “hydroxyl group-containing (meth) acrylic compound”) include caprolactone adducts of hydroxyalkyl (meth) acrylate and polyalkylene glycol mono (meth) acrylate, etc. Is mentioned.

The caprolactone adduct of hydroxyalkyl (meth) acrylate is a compound represented by the following formula (2).
CH ₂ = C (R ¹ ) COOR ² O [CO (CH ₂ ) ₅ O] _n H (2)
[In the above formula (2), R ¹ represents a hydrogen atom or a methyl group, R ² represents a divalent hydrocarbon group, and n represents a number of 1 to 10. ]
Examples of the divalent hydrocarbon group for R ² include an ethylene group, a propylene group, and a tetramethylene group.
Preferable specific examples of the hydroxyalkyl (meth) acrylate caprolactone adduct include hydroxyethyl (meth) acrylate caprolactone adduct.

  Examples of the polyalkylene glycol mono (meth) acrylate include polyethylene glycol mono (meth) acrylate and polypropylene glycol mono (meth) acrylate.

Among these compounds, a caprolactone adduct of hydroxyalkyl (meth) acrylate is preferable in that the cured product of the composition has excellent optical properties.
N representing the average number of caprolactone additions in the above formula (2) is preferably 1 or more and 3 or less. When the value of n is 1 or more, excellent mechanical properties are exhibited, and when the value of n is 3 or less, excellent optical properties (low photoelasticity) are exhibited.

  The compound is commercially available, and a caprolactone adduct of hydroxyethyl acrylate [Placcel FA1DDM manufactured by Daicel Corporation], polyethylene glycol mono (meth) acrylate [Blemmer AE-90, Blemmer PE-90 (both NOF Corporation) Product)], polypropylene glycol mono (meth) acrylate (Blenmer AP-150, Blenmer PP-1000 [both manufactured by NOF Corporation]] and the like.

1-3. The reaction (A) component of the polymer (a1) and the compound (a2) is a reaction product of the polymer (a1) and the compound (a2).
When the polymer (a1) is a polymer having an epoxy group, it is preferable to use a carboxyl group-containing (meth) acrylic compound as the compound (a2).
The reaction between the polymer having an epoxy group and the carboxyl group-containing (meth) acrylic compound may be carried out in accordance with a conventional method. The polymer having an epoxy group and the carboxyl group-containing (meth) acrylic compound are preferably present in the presence of an addition catalyst. Examples of the method include heating and stirring.
Catalysts for the addition reaction of epoxy groups and carboxyl groups include tertiary amines such as triethylamine, tripropylamine, tributylamine, dimethyllaurylamine, triethylenediamine and tetramethylethylenediamine; triethylbenzylammonium chloride, trimethylcetylammonium bromide, tetra Quaternary ammonium salts such as butylammonium bromide, quaternary phosphonium salts such as triphenylbutylphosphonium bromide and tetrabutylphosphonium bromide; and phosphine compounds such as triphenylphosphine and tributylphosphine.
Among these, it is preferable to use tetrabutylammonium bromide because it has high catalytic activity and little coloration.
As a reaction ratio of the carboxyl group-containing (meth) acrylic compound with respect to the polymer having an epoxy group, the carboxyl group-containing (meth) acrylic compound is 0.8 with respect to a total of 1 mol of epoxy groups in the polymer having an epoxy group. -1.2 mol is preferred.

  When the polymer (a1) is a polymer having an isocyanate group, it is preferable to use a carboxyl group-containing (meth) acrylic compound or a hydroxyl group-containing (meth) acrylic compound as the compound (a2).

The reaction between the polymer having an isocyanate group and the carboxyl group-containing (meth) acrylic compound may be carried out in accordance with a conventional method, and the polymer having an isocyanate group and the carboxyl group-containing (meth) acrylic compound are preferably present in the presence of an addition catalyst. Examples of the method include heating and stirring.
Examples of the catalyst for the urethanization reaction between an isocyanate group and a carboxyl group include an organometallic compound.
Examples of organometallic compounds include di-n-butyltin oxide, di-n-butyltin dilaurate, di-n-butyltin, di-n-butyltin diacetate, di-n-octyltin oxide, di-n-octyltin dilaurate, Organic tin compounds such as monobutyltin trichloride, di-n-butyltin dialkyl mercaptan, di-n-octyltin dialkyl mercaptan; organic lead compounds such as lead oleate, lead 2-ethylhexanoate, lead naphthenate, lead octenoate An organic bismuth compound such as bismuth octylate;
As the reaction ratio of the carboxyl group-containing (meth) acrylic compound to the polymer having an isocyanate group, the carboxyl group-containing (meth) acrylic compound 1.0 is used with respect to a total of 1 mol of isocyanate groups in the polymer having an isocyanate group. -1.2 mol is preferred.

The reaction between the polymer having an isocyanate group and the hydroxyl group-containing (meth) acrylic compound may be carried out according to a conventional method. The polymer having an isocyanate group and the hydroxyl group-containing (meth) acrylic compound are preferably heated in the presence of an addition catalyst. Examples include a method of stirring.
For the urethanization reaction between an isocyanate group and a hydroxyl group, the same catalyst as in the urethanization reaction described above can be used.
As a reaction ratio of the hydroxyl group-containing (meth) acrylic compound with respect to the polymer having an isocyanate group, the hydroxyl group-containing (meth) acrylic compound is 1.0 to 1 with respect to a total of 1 mol of isocyanate groups in the polymer having an isocyanate group. .2 moles are preferred.

2. Component (B) The component (B) is a (meth) acrylate polymer having a (meth) acryloyl group in the side chain which is a reaction product of the polymer (b1) and the compound (b2).
Hereinafter, the reaction of the polymer (b1), the compound (b2) and the polymer (b1) with the compound (b2) will be described.

2-1. Polymer (b1)
The polymer (b1) has in its side chain a carboxyl group or a hydroxyl group obtained by copolymerizing the compound (a2) and a monomer copolymerizable therewith [hereinafter referred to as “monomer (b12)”]. It is a (meth) acrylate polymer.

  Examples of the compound (a2) include the same compounds as described above, and preferred embodiments are also the same.

The monomer (b12) is not particularly limited as long as it is a compound that can be copolymerized with the compound (a2) and has an ethylenically unsaturated group, but is excellent in copolymerizability with the compound (a2) ( A compound having a (meth) acryloyl group is preferred.
Specific examples of the monomer (b12) include the same compounds as the monomer (a12).

  Among these compounds, the monomer (b12) is preferably methyl (meth) acrylate, more preferably methyl methacrylate, from the viewpoint of excellent optical properties of the obtained component (B). In other unsaturated compounds, the proportion of methyl methacrylate is preferably 50% by weight or more.

  The copolymerization ratio of the compound (a2) and the monomer (b12) is preferably compound (a2): monomer (b12) = 1 to 50:99 to 50 (weight ratio). By using this copolymerization split, excellent mechanical properties, particularly elongation at break can be obtained.

There is no restriction | limiting in particular as a manufacturing method of the copolymer of a compound (a2) and a monomer (b12), and well-known suspension polymerization, emulsion polymerization, block polymerization, solution polymerization etc. are mentioned using the above-mentioned compound. This method can be used.
Among these, the solution polymerization method is preferable because the polymer can be easily produced and does not contain extra impurities such as an emulsifier.
Specific examples of the method for producing the polymer include the same methods as those described above for the polymer (a1).

  As Mw of a polymer (b1), 2,000-100,000 are preferable, More preferably, it is 3,000-80,000, More preferably, it is 4,000-50,000.

2-2. Compound (b2)
The compound (b2) is a compound having a functional group capable of reacting with a carboxyl group or a hydroxyl group and a (meth) acryloyl group.
Examples of the functional group capable of reacting with a carboxyl group include an epoxy group and an isocyanate group.
Examples of the functional group capable of reacting with a hydroxyl group include an isocyanate group.

Examples of the compound (b2) include an epoxy unsaturated compound and an isocyanate unsaturated compound.
Specific examples of these compounds include the same compounds as those mentioned for the monomer (a11).

2-3. The reaction (B) component of the polymer (b1) and the compound (b2) is a reaction product of the polymer (b1) and the compound (b2).
When the polymer (b1) is a polymer having a carboxyl group, it is preferable to use an epoxy group-containing (meth) acrylic compound or an isocyanate group-containing (meth) acrylic compound as the compound (b2).
The reaction between the polymer having a carboxyl group and the epoxy group-containing (meth) acrylic compound, and the reaction between the polymer having a carboxyl group and the isocyanate group-containing (meth) acrylic compound may be carried out in accordance with conventional methods, and the same method as described above. Is mentioned.

When the polymer (b1) is a polymer having a hydroxyl group, an isocyanate group-containing (meth) acrylic compound is preferably used as the compound (b2).
The reaction between the polymer having a hydroxyl group and the isocyanate group-containing (meth) acrylic compound may be carried out in accordance with a conventional method, and examples thereof include the same method as described above.

3. The components (A) and (B) (A) and (B) each have a (meth) acryloyl group in the side chain, and the (meth) acryloyl group is not less than a certain amount from the main chain. It is a (meth) acrylate polymer at a position where the distance is maintained.

  As (A) and (B) component Mw, 2,000-100,000 are preferable in any case. By setting it to 2,000 or more and 100,000 or less, the mechanical properties of the cured product of the composition become excellent. (A) and (B) As component Mw, 3,000-80,000 are more preferable, More preferably, it is 4,000-50,000.

What is necessary is just to set suitably as an average number of the (meth) acryloyl group in (A) and (B) component according to the objective.
The average number of (meth) acryloyl groups in components (A) and (B) is preferably 1.2 to 15.0 on average per molecule, more preferably 1.2 to average. 13.0. When the number of (meth) acryloyl groups in one molecule is less than 1.2 on average, the proportion of the polymer in which (meth) acryloyl groups are not introduced increases, and the (A) component and (B) component are sufficiently incorporated into the matrix. Therefore, heat resistance, moist heat resistance and brittleness may be insufficient. On the other hand, an average of more than 15.0 is not preferable because the crosslink density is increased and the toughness of the film is poor.
The average number (f) of (meth) acryloyl groups in the component (A) can be represented by the following formula (1).

XA: number average molecular weight Mn of polymer (a1) measured by GPC
YA: molecular weight of compound unit having reactive group in polymer (a1) ZA: part by weight of compound unit having reactive group in polymer (a1) The reactive group in polymer (a1) is The compound unit has a monomer unit derived from an epoxy unsaturated compound if it is a polymer having an epoxy group, and a monomer unit derived from an isocyanate unsaturated compound if it is a polymer having an isocyanate group. To do.

  The average number (f) of (meth) acryloyl groups in the component (B) can be represented by the following formula (2).

XB: number average molecular weight Mn of polymer (b1) measured by GPC
YB: Molecular weight of the compound unit having a reactive group in the polymer (b1) ZB: Weight part of the compound unit having a reactive group in the polymer (b1) The reactive group in the polymer (b1) is The compound unit having means a monomer unit derived from the compound (a2).

4). Component (C) The component (C) is a compound having two or more ethylenically unsaturated groups other than the components (A) and (B).
(C) component is a component mix | blended in order to reduce the viscosity of the whole composition and to suppress the foaming at the time of solvent drying, and in order to adjust physical properties, such as Tg of a hardened | cured material, and a water absorption.

Examples of the ethylenically unsaturated group in component (C) include (meth) acryloyl groups and vinyl groups, with (meth) acryloyl groups being preferred.
(C) As a component, the polyfunctional (meth) acrylate which has 2 or more of (meth) acryloyl groups is preferable.

Specific examples of the polyfunctional (meth) acrylate include bisphenol A EO-modified (n = 1 to 2) di (meth) acrylate, bisphenol A di (meth) acrylate, ethylene glycol di (meth) acrylate, and diethylene glycol di (meth). Acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, polyethylene glycol (n = 5-14) di (meth) acrylate, propylene glycol di (meth) acrylate, dipropylene glycol di (meth) Acrylate, tripropylene glycol di (meth) acrylate, tetrapropylene glycol di (meth) acrylate, polypropylene glycol (n = 5-14) di (meth) acrylate, 1,3-butylene glycol Di (meth) acrylate, 1,4-butanediol di (meth) acrylate, polybutylene glycol (n = 3 to 16) di (meth) acrylate, poly (1-methylbutylene glycol) (n = 5 to 20) di (Meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate, Bifunctional (meth) acrylates such as dimethylol tricyclodecane di (meth) acrylate and spiroglycol di (meth) acrylate;
Trifunctional (meth) acrylates such as trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, tris [(meth) acryloxyethyl] isocyanurate, caprolactone-modified tris [(meth) acryloxyethyl] isocyanurate ;
More than four functionalities such as pentaerythritol tetra (meth) acrylate, ditrimethylolpropane tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, caprolactone modified dipentaerythritol hexa (meth) acrylate (Meth) acrylate and the like.
In the above, EO modification means an ethylene oxide adduct, and n means the number of repeating alkylene oxide units.

  As the component (C), only one kind of the aforementioned compounds may be used, or two or more kinds may be used in combination.

  As the component (C), among the above-mentioned compounds, dimethylol tricyclodecane di (meth) acrylate and pentaerythritol tri (meth) acrylate can be obtained because the storage modulus and Tg of the cured product can be increased and the water absorption is small. Ditrimethylolpropane tetra (meth) acrylate and the like are preferable.

5. Active energy ray-curable composition for optical film formation The composition of the present invention essentially comprises the component (A) or / and the component (B) and the component (C).
The manufacturing method of the composition of this invention should just follow a conventional method, and it can obtain it by stirring and mixing said (A)-(C) component and other components mentioned later as needed. If necessary, the mixing time can be shortened by heating.

The proportion of the component (A), the component (B) and the component (C) is 50 to 95% by weight of the component (A) based on the total amount of the component (A), the component (B) and the component (C). B) Component 50 to 95% by weight and (C) Component 5 to 50% by weight. However, when the components (A) and (B) are used in combination, the total amount is 50 to 95% by weight.
Preferably, (A) component is 50 to 85% by weight, (B) component is 50 to 85% by weight, and (C) component is 15 to 50% by weight. However, when using together (A) and (B) component, the total amount shall be 50 to 85 weight%.
When the proportion of the component (A) or / and the component (B) is less than 50% by weight, the cured product becomes brittle, and the proportion of the component (A) or / and the component (B) exceeds 95% by weight. In this case, Tg becomes lower than 120 ° C. When the proportion of the component (C) is less than 5% by weight, bubbles are generated when the organic solvent is dried and the appearance of the cured product becomes poor, and when the proportion of the component (C) exceeds 50% by weight, The cured product becomes brittle.

In addition, the composition of the present invention requires that the cured product has a Tg of 120 ° C. or higher, preferably 120 to 250 ° C., more preferably 150 to 200 ° C.
When Tg of hardened | cured material is less than 120 degreeC, heat resistance becomes inadequate, and when using hardened | cured material as a base material of a transparent conductive film, the problem of a wrinkle generation | occurrence | production at the time of film-forming of a metal oxide arises.
In the present invention, Tg is a rate of temperature increase of 2 ° C./min. Means the temperature at which the main peak of the loss tangent (tan δ) of the dynamic viscoelastic spectrum of the cured product measured in (1) becomes maximum.

Further, the composition of the present invention needs to have a water absorption of 2.0% or less of the cured product, preferably 0.5 to 2.0%, more preferably 0.5 to 1.5%. is there. A composition having a water absorption rate exceeding 2.0% takes a long time to form a vacuum during the formation of a metal oxide when the cured product is used as a base material for a transparent conductive film, which causes an increase in cost. Or the adhesion of the metal oxide is reduced.
In the present invention, the water absorption means a value measured according to the following method.
That is, a cured product of the composition is cut into 50 mm × 50 mm and used as a test piece. Based on the water absorption measurement based on JIS K7209, this test piece is heated at 50 degreeC for 24 hours, and after drying hardened | cured material completely, it cools in a desiccator and weighs a test piece (W1). Next, the test piece is immersed in distilled water at 23 ° C. for 24 hours, and after taking out, the water on the surface of the test piece is gently wiped and weighed (W2).
The water absorption means a result calculated according to the following formula based on the obtained results of W1 and W2.
Water absorption (%) = (W2−W1) / W1 × 100

The composition of the present invention comprises the components (A) to (C) as essential components, but various components can be blended depending on the purpose.
Specifically, the other components include a photopolymerization initiator (hereinafter referred to as “component (D)”), an organic solvent (hereinafter referred to as “component (E)”), and one ethylenically unsaturated group. Examples include compounds [hereinafter referred to as “component (F)”], plasticizers, polymerization inhibitors or / and antioxidants, and light resistance improvers.
Hereinafter, these components will be described.

5-1. (D) Component (D) A component is a photoinitiator.
(D) A component is a component mix | blended when an ultraviolet-ray and visible light are used as an active energy ray. When an electron beam is used as the active energy ray, it is not always necessary to add it, but a small amount can be added as necessary in order to improve curability.

As component (D), benzyldimethyl ketal, benzyl, benzoin, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one 1- [4- (2-hydroxyethoxy) -phenyl] -2-hydroxy-2-methyl-1-propan-1-one, oligo [2-hydroxy-2-methyl-1- [4-1- (methylvinyl) phenyl] Propanone, 2-hydroxy-1- [4- [4- (2-hydroxy-2-methyl-propionyl) -benzyl] -phenyl] -2-methylpropan-1-one, 2-methyl-1- [4- (methylthio) )] Phenyl] -2-morpholinopropan-1-one, 2 Benzyl-2-dimethylamino-1- (4-morpholinophenyl) butan-1-one, 2-dimethylamino-2- (4-methylbenzyl) -1- (4-morpholin-4-yl-phenyl) -butane-1 -Aromatic ketone compounds such as ON, Adekaoptomer N-1414 (manufactured by ADEKA), phenylglyoxylic acid methyl ester, ethyl anthraquinone, phenanthrenequinone;
Benzophenone, 2-methylbenzophenone, 3-methylbenzophenone, 4-methylbenzophenone, 2,4,6-trimethylbenzophenone, 4-phenylbenzophenone, 4- (methylphenylthio) phenylphenylmethane, methyl-2-benzophenone, 1- [4- (4-Benzoylphenylsulfanyl) phenyl] -2-methyl-2- (4-methylphenylsulfonyl) propan-1-one, 4,4′-bis (dimethylamino) benzophenone, 4,4′-bis ( Benzophenone compounds such as diethylamino) benzophenone, N, N′-tetramethyl-4,4′-diaminobenzophenone, N, N′-tetraethyl-4,4′-diaminobenzophenone and 4-methoxy-4′-dimethylaminobenzophenone ;
Bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, ethyl- (2,4,6-trimethylbenzoyl) phenylphosphinate and bis (2, Acylphosphine oxide compounds such as 6-dimethoxybenzoyl) -2,4,4-trimethylpentylphosphine oxide;
Thioxanthone, 2-chlorothioxanthone, 2,4-diethylthioxanthone, isopropylthioxanthone, 1-chloro-4-propylthioxanthone, 3- [3,4-dimethyl-9-oxo-9H-thioxanthone-2-yl] oxy]- Thioxanthone compounds such as 2-hydroxypropyl-N, N, N-trimethylammonium chloride and fluorothioxanthone;
Acridone compounds such as acridone, 10-butyl-2-chloroacridone;
1,2-octanedione 1- [4- (phenylthio) -2- (O-benzoyloxime)] and ethanone 1- [9-ethyl-6- (2-methylbenzoyl) -9H-carbazol-3-yl] Oxime esters such as -1- (O-acetyloxime);
2- (o-chlorophenyl) -4,5-diphenylimidazole dimer, 2- (o-chlorophenyl) -4,5-di (m-methoxyphenyl) imidazole dimer, 2- (o-fluorophenyl) -4,5-phenylimidazole dimer, 2- (o-methoxyphenyl) -4,5-diphenylimidazole dimer, 2- (p-methoxyphenyl) -4,5-diphenylimidazole dimer, 2 2,4,5-triarylimidazole such as 2,4-di (p-methoxyphenyl) -5-phenylimidazole dimer and 2- (2,4-dimethoxyphenyl) -4,5-diphenylimidazole dimer Dimer; and acridine derivatives such as 9-phenylacridine and 1,7-bis (9,9'-acridinyl) heptane.

  These compounds may be used alone or in combination of two or more.

As the blending ratio of component (D), the total amount of components (A), (B) and (C), and when blending component (F) described later, (A), (B), (C) and ( F) 0.01 to 10 parts by weight is preferable with respect to 100 parts by weight of the total amount of components, and more preferably 0.1 to 5 parts by weight.
Hereinafter, the components (A), (B) and (C) or the components (A), (B), (C) and (F) are referred to as “curable components”.
By setting the blending ratio of the component (D) to 0.01% by weight or more, the composition can be cured with an appropriate amount of ultraviolet light or visible light, and the productivity can be improved. By doing, it can be made the thing excellent in the weather resistance and transparency of hardened | cured material.

5-2. Component (E) The composition of the present invention preferably contains an organic solvent of component (F) for the purpose of improving the coating property to the substrate.

Specific examples of the organic solvent of component (E) include hydrocarbon solvents such as n-hexane, benzene, toluene, xylene, ethylbenzene, and cyclohexane;
Methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, isobutyl alcohol, 2-methoxyethanol, 2-ethoxyethanol, 2- (methoxymethoxy) ethanol, 2-isopropoxyethanol, 2-butoxy Ethanol, 2-isopentyloxyethanol, 2-hexyloxyethanol, 2-phenoxyethanol, 2-benzyloxyethanol, furfuryl alcohol, tetrahydrofurfuryl alcohol, diethylene glycol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, diethylene glycol monobutyl ether, 1 -Methoxy-2-propanol, 1-ethoxy-2-propanol and propylene glycol monomethyl Alcohol solvents such as ether;
Ether solvents such as tetrahydrofuran, dioxane, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, ethylene glycol dibutyl ether, bis (2-methoxyethyl) ether, bis (2-ethoxyethyl) ether and bis (2-butoxyethyl) ether;
Acetone, methyl ethyl ketone, methyl-n-propyl ketone, diethyl ketone, butyl methyl ketone, methyl isobutyl ketone, methyl pentyl ketone, di-n-propyl ketone, diisobutyl ketone, phorone, isophorone, cyclopentanone, cyclohexanone, methylcyclohexanone, etc. Ketone solvents;
Ester solvents such as ethyl acetate, butyl acetate, isobutyl acetate, methyl glycol acetate, propylene glycol monomethyl ether acetate, cellosolve acetate;
Examples include aprotic polar solvents such as N, N-dimethylformamide, N, N-dimethylacetamide, dimethyl sulfoxide, N-methyl-2-pyrrolidone and γ-butyrolactone.

As the component (E), one or more of the aforementioned compounds can be used.
As an organic solvent, you may add separately and may use it as it is, without isolate | separating the organic solvent used by manufacture of (A) component.

  The proportion of the component (E) may be appropriately set, but is preferably 10 to 90% by weight, more preferably 20 to 80% by weight in the composition.

5-3. Component (F) The component (F) is a compound having one ethylenically unsaturated group, and is a component to be blended as necessary for the purpose of reducing the viscosity of the entire composition.
Examples of the ethylenically unsaturated group in component (F) include a (meth) acryloyl group and a vinyl group, with a (meth) acryloyl group being preferred.

  Specific examples of the component (F) include compounds having one (meth) acryloyl group [hereinafter, “monofunctional (meth) acrylate”, N-vinyl-2-pyrrolidone, and the like.

  Specific examples of the monofunctional (meth) acrylate include isobornyl (meth) acrylate, dicyclopentenyl (meth) acrylate, dicyclopentanyl (meth) acrylate, cyclohexyl (meth) acrylate, trimethylcyclohexyl (meth) acrylate, 1- Adamantyl (meth) acrylate, methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, n-butyl (meth) acrylate, i-butyl (meth) acrylate, t-butyl (meth) acrylate, hexyl ( (Meth) acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, glycidyl (meth) acrylate Dimethylaminoethyl (meth) acrylate, diethylaminoethyl (meth) acrylate, benzyl (meth) acrylate, allyl (meth) acrylate, 2-ethoxyethyl (meth) acrylate, phenoxyethyl (meth) acrylate, о-phenylphenol EO modification ( n = 1 to 4) (meth) acrylate, p-cumylphenol EO modified (n = 1 to 4) (meth) acrylate, phenyl (meth) acrylate, о-phenylphenyl (meth) acrylate, p-cumylphenyl (meta ) Acrylate, N- (meth) acryloylmorpholine, N-vinylformamide, N- (meth) acryloyloxyethyl hexahydrophthalimide, N- (meth) acryloyloxyethyl tetrahydrophthalimide, and the like.

  (F) As a mixture ratio of a component, 1 to 10 weight% is preferable in 100 weight part of total amounts of a sclerosing | hardenable component, More preferably, it is 1 to 8 weight.

5-4. For the purpose of imparting flexibility to the cured plasticizer and improving brittleness, a plasticizer can be added. Specific examples of the plasticizer include dialkyl phthalates such as dioctyl phthalate and diisononyl phthalate, dialkyl esters of adipic acid such as dioctyl adipate, phosphate esters such as sebacic acid ester, azelaic acid ester and tricresyl phosphate, polypropylene Examples thereof include liquid polyether polyols such as glycol, liquid polyester polyols such as polycaprolactone diol and 3-methylpentanediol adipate.
The blending ratio of these plasticizers may be set as appropriate, but is preferably 5 to 30 parts by weight, more preferably 5 to 20 parts by weight with respect to 100 parts by weight of the curable component.
When the blending ratio of the plasticizer is 5 parts by weight or more, flexibility is exhibited, and when it is 30 parts by weight or less, toughness is maintained.

5-5. Polymerization inhibitor or / and antioxidant It is preferable to add a polymerization inhibitor or / and an antioxidant to the composition of the present invention because the storage stability of the composition of the present invention can be improved.
As the polymerization inhibitor, hydroquinone, hydroquinone monomethyl ether, 2,6-di-tert-butyl-4-methylphenol, and various phenolic antioxidants are preferable. A secondary antioxidant or the like can also be added.
The total blending ratio of these polymerization inhibitors or / and antioxidants is preferably 0.001 to 3 parts by weight, more preferably 0.01 to 0 parts per 100 parts by weight of the total amount of the curable components. .5 parts by weight.

5-6. The composition of the light resistance improver present invention, the light resistance improving agent such as an ultraviolet absorber or a light stabilizer may be added.
Examples of the ultraviolet absorber include 2- (2′-hydroxy-5-methylphenyl) benzotriazole, 2- (2′-hydroxy-3 ′, 5′-di-t-butylphenyl) benzotriazole, 2- (2 Benzotriazole compounds such as'-hydroxy-3'-t-butyl-5'-methylphenyl)benzotriazole;
Triazine compounds such as 2,4-bis (2,4-dimethylphenyl) -6- (2-hydroxy-4-iso-octyloxyphenyl) -s-triazine;
2,4-dihydroxy-benzophenone, 2-hydroxy-4-methoxy-benzophenone, 2-hydroxy-4-methoxy-4'-methylbenzophenone, 2,2'-dihydroxy-4-methoxybenzophenone, 2, 4, 4 ' -Trihydroxybenzophenone, 2,2 ', 4,4'-tetrahydroxybenzophenone, 2,3,4,4'-tetrahydroxybenzophenone, 2,3', 4,4'-tetrahydroxybenzophenone, or 2,2 Examples include benzophenone compounds such as'-dihydroxy-4,4'-dimethoxybenzophenone.
Examples of the light stabilizer include N, N′-bis (2,2,6,6-tetramethyl-4-piperidyl) -N, N′-diformylhexamethylenediamine, bis (1,2,6,6). -) Pentamethyl-4-piperidyl) -2- (3,5-ditertiarybutyl-4-hydroxybenzyl) -2-n-butylmalonate, bis (1,2,2,6,6-pentamethyl-4- Low molecular weight hindered amine compounds such as piperidinyl) sebacate; N, N′-bis (2,2,6,6-tetramethyl-4-piperidyl) -N, N′-diformylhexamethylenediamine, bis (1,2 Hindered amine light stabilizers such as high molecular weight hindered amine compounds such as 2,6,6-pentamethyl-4-piperidinyl) sebacate.
The blending ratio of the light fastness improver is preferably 0 to 5 parts by weight, more preferably 0 to 1 part by weight with respect to 100 parts by weight of the total amount of the curable component.

6). Method of Use The composition of the present invention can employ various methods of use depending on the purpose of forming the optical film.
Specifically, a method of applying a composition to a substrate and irradiating it with an active energy ray to cure, applying a composition to a substrate and bonding it to another substrate, and then irradiating with an active energy ray. And a curing method, a method of pouring the composition into a mold having a recess, and curing by irradiation with active energy rays.

As the substrate, any of a peelable substrate and a substrate having no releasability (hereinafter referred to as “non-releasing substrate”) can be used.
Examples of the peelable substrate include a release-treated film and a surface untreated film having peelability (hereinafter collectively referred to as “release material”).
Examples of the release material include silicone-treated polyethylene terephthalate film, surface untreated polyethylene terephthalate film, surface untreated cycloolefin polymer film, and surface untreated OPP film (polypropylene).
In order to suppress the haze of the cured product of the composition of the present invention to 1.0% or less, it is preferable to use a surface untreated polyethylene terephthalate film or a surface untreated OPP film (polypropylene).

In order to achieve low haze or impart surface smoothness to the optical film obtained from the composition of the present invention, the surface roughness (centerline average roughness) Ra is 0.15 μm or less as a peelable substrate. It is preferable to use a base material of 0.001 to 0.100 μm. Furthermore, the haze is preferably 3.0% or less.
Specific examples of the substrate include a surface untreated polyethylene terephthalate film and a surface untreated OPP film (polypropylene).
In the present invention, the surface roughness Ra means a value obtained by measuring the surface roughness of the film and calculating an average roughness.

  Examples of the non-releasable base material include various plastics other than the above, cellulose acetate resins such as polyvinyl alcohol, triacetyl cellulose and diacetyl cellulose, acrylic resins, polyesters, polycarbonates, polyarylates, polyethersulfones, norbornene, etc. And cyclic polyolefin resins having a cyclic olefin as a monomer.

In coating the composition of the present invention, as a composition, in order to prevent the occurrence of foreign matters and the occurrence of defects such as voids in the obtained optical film, or to have excellent optical properties, the raw material components are used. It is preferable to use a purified product after stirring and mixing.
As a method for purifying the composition, a method of filtering the composition is simple and preferable. Examples of the filtration method include pressure filtration.
The filtration accuracy is preferably 10 μm or less, more preferably 5 μm or less. The lower the filtration accuracy, the better. However, if the filter accuracy is too small, the filter is likely to be clogged, and the filter replacement frequency increases and the productivity is lowered. Therefore, the lower limit is preferably 0.1 μm.

  The coating method may be appropriately set according to the purpose, and conventionally known bar coat, applicator, doctor blade, knife coater, comma coater, reverse roll coater, die coater, lip coater, gravure coater, micro gravure coater, etc. The method of coating with is mentioned.

Examples of active energy rays include electron beams, ultraviolet rays, and visible rays. Among these, an electron beam is more preferable in that it is not always necessary to add a photopolymerization initiator and the cured product is excellent in heat resistance and light resistance.
Further, when the transparent conductive film is formed on the optical film by a vacuum process such as a vacuum deposition method or a sputtering method, it is also preferable in that the outgas such as a photopolymerization initiator residue or a decomposition product in the film does not cause a problem.
What is necessary is just to set suitably irradiation conditions, such as a dose and irradiation intensity in active energy ray irradiation, according to the composition to be used, a base material, a purpose, etc.

7). Optical Film The composition of the present invention can be preferably used for the production of an optical film.
Hereinafter, the optical film will be described.
In the following, a part of the description will be given with reference to FIGS.

7-1. Manufacturing method of optical film As a manufacturing method of an optical film, what is necessary is just to follow a conventional method, for example, after apply | coating a composition to a base material, it can irradiate with an active energy ray and can manufacture.

FIG. 1 shows an example of a preferable method for producing an optical film composed of a release material / cured product.
In FIG. 1, (1) means a release material.
When the composition is a solventless type (FIG. 1: F1), the composition is applied to a release material [FIG. 1: (1)]. When the composition contains an organic solvent or the like (FIG. 1: F2), the composition is applied to a release material [FIG. 1: (1)] and then dried to evaporate the organic solvent or the like (FIG. 1: 1). -1).
By irradiating an active energy ray to the sheet in which the composition layer (2) is formed on the release material, an optical film composed of the release material / cured product is obtained. The active energy ray is usually irradiated from the composition layer side, but can also be irradiated from the release material side.
In the above, if a release material is used as the substrate (1), an optical film composed of the release material / cured product can be produced.

  The coating amount of the composition of the present invention may be appropriately selected according to the application to be used, but it is preferable that the coating is performed so that the film thickness after drying the organic solvent or the like is 5 to 200 μm. Preferably it is 10-100 micrometers.

When the composition contains an organic solvent or the like, it is heated and dried after coating to evaporate the organic solvent or the like.
As a heating / drying method, a method of passing through a furnace equipped with a heating device, or it can be carried out by blowing air,
The heating / drying conditions may be appropriately set according to the organic solvent used, and examples thereof include a method of heating to a temperature of 40 to 150 ° C.
As the composition after heating and drying, the proportion of the organic solvent is preferably 1% by weight or less.

  What is necessary is just to set suitably irradiation conditions, such as a dose and irradiation intensity in active energy ray irradiation, according to the composition to be used, a base material, a purpose, etc.

  FIG. 2 shows an example of a preferable method for producing an optical film composed of a release material / cured product / release material.

In FIG. 2, (1), (3), and (4) mean release materials.
When the composition is a solventless type (FIG. 2: F1), the composition is applied to a release material [FIG. 2: (1)]. When the composition contains an organic solvent or the like (FIG. 2: F2), the composition is applied to a release material [FIG. 2: (1)] and then dried to evaporate the organic solvent (FIG. 2: 2). -1). The composition layer (2) is laminated with the release material (3) and then irradiated with active energy rays, or after being irradiated with active energy rays, the release material (4) is laminated to obtain a release material, a cured product and a release material. An optical film formed in this order is obtained.

Although the example which used the mold release material as a base material was described in the said FIG. 1 and 2, an optical film can also be manufactured using a non-mold release base material.
For example, in FIG. 1, a non-releasable base material is used instead of the release material of (1), and it is cured by irradiating with active energy in the same manner as described above. A film can also be produced.
Further, in FIG. 2, a non-releasing substrate is used as the release material of any of (1), (3) and (4), and cured by irradiation with active energy rays in the same manner as described above. An optical film composed of a release material / cured product / non-releasing substrate or an optical film composed of a non-releasing substrate / cured material / non-releasing substrate can also be produced.

  In the above example, the optical film is produced by applying the composition to a substrate. However, when producing an optical film having a large film thickness, the composition is formed on a mold having a specific recess. An optical film can also be produced by pouring an object and irradiating active energy rays in the same manner as described above to cure the composition.

7-2. Use of optical film The optical film formed from the composition of the present invention can be used for various optical uses. More specifically, films used for liquid crystal display devices such as polarizer protective films for polarizing plates, support films for lens sheets such as support films for prism sheets, and light guide films, and touch panel integrated liquid crystal display devices, various functions Base film of a conductive film (for example, hard coat film, decorative film, transparent conductive film) and a film with a surface shape (for example, moth-eye type antireflection film or film with texture structure for solar cell), solar cell, etc. Applications such as light-resistant (weather-resistant) film, LED illumination / organic EL illumination film, and transparent heat-resistant film for flexible electronics.
The optical film formed from the composition of the present invention is excellent in heat resistance and has a low water absorption rate and in-plane retardation, and therefore can be preferably used for a polarizer protective film and a transparent conductive film.
As described above, the optical film formed from the composition of the present invention has excellent heat resistance, so that appearance defects due to vacuum film formation of metal oxides and the like do not occur, and because of excellent bending resistance, roll-to- Since roll conveyance is possible, the transparent conductive film can be preferably used.

  Hereinafter, the present invention will be described more specifically with reference to examples and comparative examples. In the following, “parts” means parts by weight.

1) Manufacturing example
(1) Production Example A1 [Production of Component (A)]
In a 500 mL reaction vessel equipped with a stirrer, a thermometer and a condenser, methyl methacrylate (hereinafter referred to as “MMA”): 13.5 g, glycidyl methacrylate (hereinafter referred to as “GMA”): 1.5 g, methyl ethyl ketone (hereinafter referred to as “ MEK ”): 65 g was charged and uniformly dissolved at room temperature.
While stirring the contents of the flask, the internal temperature was raised to 78 ° C. under a nitrogen atmosphere, and after the internal temperature became constant, 2,2′-azobis-2,4-dimethylvaleronitrile [Wako Pure Chemical Industries, Ltd.] V-65 manufactured by Kogyo Co., Ltd. Hereinafter referred to as “V-65”]: 0.3 g of MEK: 2.0 g was added. Two minutes later, 85 g of a mixed solution of 76.5 g of MMA and 8.5 g of GMA was added over 4 hours, while a polymerization initiator solution consisting of V-65: 2.7 g and MEK: 18 g was added to 5 g. Each was added continuously over time. Thereafter, the mixture was stirred with heating for 2 hours.
After completion of the continuous addition, aging was carried out for 2 hours while maintaining the internal temperature at 78 ° C. to obtain a polymer solution (solid content 54%) having an epoxy group.
This solution was again heated to 78 ° C. and stirred at 180 rpm for 1 hour while blowing a 5% oxygen-nitrogen mixture. Thereafter, 2,6-di-t-butyl-4-methylphenol (hereinafter referred to as “BHT”): 0.03 g as a polymerization inhibitor, and tetrabutylammonium bromide (hereinafter referred to as “TBAB”) as a catalyst: 0. 5 g, Aronix M-5300 [Caprolactone adduct of acrylic acid, Mn: 300, average addition number of caprolactone: 2, manufactured by Toagosei Co., Ltd.]: 21.2 g, MEK: 8 g were added, and the mixture was heated and stirred for 48 hours. . Thereafter, the acid value was measured to confirm that it was 2 mgKOH / g or less, and the reaction was completed. As a result, a polymer solution “ULP-1” (solid content: 53%) as component (A) was obtained.
Regarding the Mn and Mw of the obtained ULP-1, the average molecular weight in terms of polystyrene was measured by GPC (solvent: tetrahydrofuran, column: HSPgel HR MB-L manufactured by Waters), and the results were Mn5,090 and Mw23,800. . Moreover, from the Mn and the charged composition, the number (f) of acrylate groups per polymer chain was calculated as an average: 3.4.
The physical properties of the reaction raw materials and the resulting polymer are summarized in Table 1. In Table 1, the number in the column of each compound means g. In Table 1, the description of MEK as an organic solvent is omitted.

(2) Production Example A2 [Production of Component (A)]
A component (A) was produced in the same manner as in Production Example A1, except that the type and amount of raw materials were changed as shown in Table 1.

(3) Production Example B1 [Production of Component (B)]
Component (B) was produced according to the same method as in Production Example A1, except that the type and amount of raw materials were changed as shown in Table 2.

2) Examples
(1) Examples 1 to 7 and Comparative Examples 1 to 4 (Production of Composition)
Each raw material was put into a stainless steel container at a ratio shown in Table 3 and Table 4, and stirred with a magnetic stirrer while heating to obtain a composition.

Abbreviations in Tables 3 and 4 mean the following.
DCPA [dimethylol tricyclodecane diacrylate, light acrylate DCP-A manufactured by Kyoeisha Chemical Co., Ltd.]
IRG184 [1-hydroxycyclohexyl phenyl ketone, Irgacure 184 manufactured by BASF Japan Ltd.]

(2) Examples F1 to F5, Comparative Examples F1 to F4 (Production of optical film by electron beam curing)
Examples 1 to 5 and Comparative Examples 1 to 4 were prepared on a film “Lumirror 188-T60” (surface untreated polyethylene terephthalate film, thickness 188 μm, hereinafter referred to as “Lumirror”) manufactured by Toray Industries, Inc. having a width of 300 mm and a length of 300 mm. The electron beam curable composition obtained in (1) was coated with an applicator so that the film thickness after drying at 120 ° C. for 10 minutes was 100 μm.
Thereafter, the composition layer is irradiated with an electron beam under the conditions of an acceleration voltage of 200 kV, a dose of 150 kGy (adjusted by a beam current and a conveyance speed), and an oxygen concentration of 300 ppm or less by an electron beam irradiation apparatus manufactured by NHV Corporation. An optical film was obtained.
After curing, it was peeled off from Lumirror and used for the evaluation described later. The results are shown in Table 5.

(3) Examples F6 to F7 (Production of optical film by ultraviolet curing)
The UV curable composition obtained in Examples 6 to 7 was applied to a Lumirror having a width of 300 mm and a length of 300 mm with an applicator so that the film thickness after drying at 120 ° C. for 10 minutes was 100 μm.
Thereafter, the composition layer is coated with a conveyor type ultraviolet irradiation device (high pressure mercury lamp, 365 nm irradiation intensity 400 mW / cm ² (measured value of UV POWER PUCK manufactured by Fusion UV Systems Japan Co., Ltd.)). ), The conveyor speed was adjusted, and ultraviolet light was irradiated with an integrated light amount of 1,000 mJ / cm ² to obtain an optical film.
After curing, it was peeled off from Lumirror and used for the evaluation described later. The results are shown in Table 5.

3) Evaluation method
(1) Film appearance About the appearance of the optical film obtained by the Example and the comparative example, it was observed visually whether there existed the bubble which generate | occur | produced at the time of solvent drying. The case where bubbles were not confirmed was evaluated as “◯”, and the case where bubbles were confirmed was evaluated as “x”. The results are shown in Table 5.

(2) Tg (glass transition temperature)
The dynamic viscoelasticity measurement of the optical films obtained in Examples and Comparative Examples was performed at a temperature of 25 to 200 ° C. and a frequency of 10 Hz, and the temperature at which the tan δ value was maximum was defined as Tg. The results are shown in Table 5.

(3) Water absorption rate Based on the water absorption rate measurement based on JIS K7209, after the test piece cut out to 50 mm x 50 mm from the optical film obtained by the Example and the comparative example was dried at 50 degreeC for 24 hours, at 23 degreeC The water absorption after water immersion for 24 hours was measured. The results are shown in Table 5.

(4) Bending resistance Based on a bending resistance test (cylindrical mandrel method) based on JIS K5600-5-1, the optical films obtained in Examples and Comparative Examples were wound around a steel bar having a diameter of 2 mm, and cracks were observed. Whether or not it occurred was visually observed. The case where no crack was confirmed was evaluated as “◯”, and the case where crack was confirmed was evaluated as “x”. The results are shown in Table 5.

(5) In-plane retardation retardation measuring device [KOBRA-WR manufactured by Oji Scientific Instruments Co., Ltd.] In-plane retardation of optical films obtained in Examples and Comparative Examples (hereinafter referred to as “0 ° Re”) ) Was measured. The results are shown in Table 5.

Examples F1 to F7 are optical films obtained from the compositions of Examples 1 to 7 which are the compositions of the present invention, and all of the film appearance, flex resistance and in-plane retardation were excellent.
On the other hand, Comparative Examples F1 and F3 are obtained from the compositions of Comparative Examples 1 and 3 that do not contain the component (C), respectively, and both of them have a Tg of the cured product of less than the lower limit of 120 ° C. of the present invention. Although it is an optical film and has excellent bending resistance and in-plane retardation, it has bubbles in the cured product.
In Comparative Examples F2 and F4, the components (A) and (B) are less than the lower limit of 50% by weight of the blending ratio of the present invention, and the component (C) is the upper limit of 50% by weight of the blending ratio of the present invention. It was an optical film obtained from the compositions of Comparative Examples 2 and 4 that exceeded the above values, and was excellent in film appearance and in-plane retardation, but was brittle with cracks in the bending resistance test.

  The active energy ray-curable composition for forming an optical film of the present invention can be suitably used for the production of an optical film.

Claims (17)

The following (A) component or / and (B) component, and (C) component containing composition, (A) on the basis of the total amount of (A) component, (B) component, and (C) component (A) 50 to 95% by weight of component, 50 to 95% by weight of component (B) [However, when components (A) and (B) are used in combination, the total amount is 50 to 95% by weight) and component (C) 5 to 50% by weight,
The glass transition temperature of the cured product is 120 ° C or higher,
An active energy ray-curable composition for forming an optical film or sheet in which the water absorption of the cured product is 2.0% or less.
Component (A): (meth) acrylate polymer (a1) [hereinafter referred to as “polymer (a1)”] having a functional group capable of reacting with a carboxyl group or a hydroxyl group in the side chain, a carboxyl group or a hydroxyl group and ( A compound having a (meth) acryloyl group and having a (meth) acryloyl group in the side chain which is a reaction product with the compound (a2) having a number average molecular weight of 180 or more (hereinafter referred to as “compound (a2)”) Acrylate polymer (B) component: (meth) acrylate polymer (b1) having a carboxyl group or a hydroxyl group in the side chain obtained by copolymerizing compound (a2) and a monomer copolymerizable therewith A (meth) acryloyl group-containing (meth) acrylic group is present in the side chain which is a reaction product of the compound (b2) having a carboxyl group or a functional group capable of reacting with a hydroxyl group and a (meth) acryloyl group. Rate-based polymer component (C): (A) and (B) a compound having two or more ethylenically unsaturated groups other than the component   The active energy ray-curable composition for optical film or sheet formation according to claim 1, wherein the polymer (a1) is a (meth) acrylate polymer having an epoxy group in a side chain.   The active energy ray-curable composition for optical film or sheet formation according to claim 2, wherein the compound (a2) is a compound having a carboxyl group and is a caprolactone adduct of (meth) acrylic acid.   The active energy ray-curable composition for forming an optical film or sheet according to claim 1, wherein the polymer (a1) is a (meth) acrylate polymer having an isocyanate group in a side chain.   The active energy ray-curable composition for optical film or sheet formation according to claim 4, wherein the compound (a2) is a compound having a hydroxyl group and is a caprolactone adduct of hydroxyalkyl (meth) acrylate.   The active energy ray-curable composition for optical film or sheet formation according to claim 4, wherein the compound (a2) is a compound having a carboxyl group and is a caprolactone adduct of (meth) acrylic acid.   The active energy ray-curable composition for optical film or sheet formation according to any one of claims 1 to 6, wherein the component (C) includes a compound having two or more (meth) acryloyl groups.   Furthermore, the active energy ray hardening-type composition for optical film or sheet | seat formation of any one of Claims 1-7 containing an organic solvent.   An electron beam curable composition for forming an optical film or sheet comprising the composition according to any one of claims 1 to 8.   The cured product of the composition according to any one of claims 1 to 9, wherein the cured product is formed into a film or a sheet, and has a glass transition temperature of 120 ° C or higher and a water absorption of 2.0. % Optical film or sheet.   The optical film which irradiates an active energy ray from the coating surface side or a film or a sheet-like base material side, after apply | coating the composition of any one of Claims 1-9 to a film or a sheet-like base material. Or the manufacturing method of a sheet | seat.   The manufacturing method of the optical film or sheet | seat of Claim 11 which irradiates an electron beam as an active energy ray.   The method for producing an optical film or sheet according to claim 11 or 12, wherein the film or sheet-like substrate is a peelable substrate.   After apply | coating the composition of any one of Claims 1-9 to a film or a sheet-like base material, and bonding another film or sheet-like base material to the coating surface of a composition, the said The manufacturing method of the optical film or sheet | seat which irradiates an active energy ray from the either side of a film or a sheet-like base material.   The manufacturing method of the optical film or sheet | seat of Claim 14 which irradiates an electron beam as an active energy ray.   The method for producing an optical film or sheet according to claim 14 or 15, wherein either one or both of the film and the sheet-like substrate is a peelable substrate.   The transparent conductive film which has a transparent conductor layer on the single side | surface or both surfaces of the optical film or sheet | seat of Claim 10.

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