JP6884045B2 - Manufacturing method of anti-glare hard coat film and anti-glare hard coat film - Google Patents

Description

The present invention relates to an antiglare hard coat film and a method for producing an antiglare hard coat film.
In particular, the present invention relates to an antiglare hard coat film capable of effectively preventing white tea and the like, and an efficient method for producing such an antiglare hard coat film.

Conventionally, in displays such as tablet terminals and car navigation systems, there has been a problem that external light is reflected on the screen display surface, making it difficult to see the displayed image.
On the other hand, when these displays are displayed in black, a phenomenon in which the screen display surface appears to be white-brown (hereinafter referred to as “white-brown”) has been observed, and with the recent increase in size of displays, such a problem can be solved. It is becoming more important.

Therefore, as a means for solving the problem of external light reflection, a technique using an antiglare hard coat material having an antiglare hard coat layer has been proposed.
That is, in such an antiglare hard coat layer, when forming the hard coat layer, a method of roughening the surface of the hard coat layer by a physical method, and mixing a filler in the hard coat agent for forming the hard coat layer. There are a method, a method of mixing two incompatible components with a hard coat agent for forming a hard coat layer, and a method of utilizing the phase separation between them.
In each of these measures, the surface of the hard coat layer, that is, the surface of the hard coat layer opposite to the plastic base material is set as the surface of the hard coat layer (hereinafter, the same applies), and the surface thereof is referred to. By forming fine irregularities, the specular reflection of external light is suppressed and the reflection of external light such as a fluorescent lamp is prevented.

For example, a transparent base film containing large-diameter fine particles and small-diameter fine particles having a larger specific gravity and a smaller particle size than the large-diameter fine particles, which is an antiglare layer having a predetermined thickness and having a large-diameter fine particles. There has been proposed an antiglare film in which antiglare layers having a volume ratio of 0.5% or more and 40% or less and a volume ratio of small diameter fine particles of 15% or more and 65% or less are laminated (Patent Document 1). reference)
Here, as the large-diameter fine particles, resin particles such as acrylic resin having an average particle size of 0.1 to 5 μm are disclosed, and as the small-diameter fine particles, zirconium oxide having an average particle size of 0.01 to 0.1 μm is disclosed. And inorganic particles such as silica are disclosed.

Japanese Unexamined Patent Publication No. 2016-133722 (Claims)

However, the antiglare film disclosed in Patent Document 1 uses a plurality of types of fillers to suppress glare on the screen (hereinafter, may be simply referred to as “glare”) while visually recognizing an image. Although an antiglare film capable of ensuring the properties has been disclosed, it was not intended to suppress the white-brownness.
Not only that, because the large-diameter fine particles are organic fine particles and the average particle size is relatively large, it is not possible to obtain an antiglare film having a thin antiglare layer. When the antiglare layer is thick, there is a problem that the antiglare film is curled.
In addition, there is a problem that the organic fine particles easily fall off from the surface of the hard coat layer, so that sufficient scratch resistance cannot be obtained, and the antiglare property tends to be further lowered with time.

Therefore, the present inventors have made diligent efforts in view of the above circumstances, and as a result, at least three kinds of particles are blended in a predetermined ratio in the material for forming the antiglare hard coat layer, and the antiglare hard coat is applied. The present invention is completed by limiting the layer thickness to a predetermined value or less.
That is, an object of the present invention is to effectively prevent white-brownness by using a plurality of types of particles in combination at a predetermined ratio, and to have excellent antiglare properties and the like, and further, an antiglare hard coat layer. Provided are an antiglare hard coat film having a high surface hardness and less curl generation even if the thickness is relatively thin, and an efficient method for producing such an antiglare hard coat film. To do.

According to the present invention, an antiglare hard coat film having an antiglare hardcoat layer on the surface of a plastic base material, wherein the antiglare hardcoat layer is formed.
(A) With respect to 100 parts by mass of active energy ray-curable resin as a component
(B1) Silica particles as a component were added to 5 to 25 parts by mass.
(B2) High-refractive index particles having an average particle size in the range of 1 to 500 nm as a component, and 3 to 30 high-refractive index particles as inorganic fine particles having a refractive index of 1.8 or more. By mass and
(B3) Resin particles as a component, 4 to 25 parts by mass,
It was derived from antiglare hard coat layer-forming material containing a less antiglare hard coat layer thickness of 8 [mu] m, an average particle diameter of the silica particles to a value within the range of 2.1～10Myuemu, the resin particles The average particle size is in the range of 0.5 to 2 μm, and the silica particles are projected from the surface of the antiglare hard coat layer on the side opposite to the plastic base material. A dazzling hard coat film is provided, which can solve the above-mentioned problems.
That is, according to the antiglare hard coat film of the present invention, the antiglare hard coat layer contains at least three kinds of particles (B1 to B3) in a predetermined ratio, and the thickness thereof is set to a predetermined value or less. By limiting, it means the surface of the antiglare hardcoat layer (the other surface of the antiglare hardcoat layer on the opposite side of the plastic substrate on which the antiglare hardcoat layer is provided). The same applies hereinafter.) Therefore, the silica particles can be surely and stably projected.
Further, by using the high refractive index particles whose average particle size is controlled in this way, it is possible to more effectively prevent the white browning property in combination with the predetermined silica particles and resin particles, and also to have more excellent antiglare property. Etc. can be obtained.
Therefore, it is possible to effectively prevent white browning, and it has excellent antiglare properties. Furthermore, even if the thickness of the antiglare hard coat layer is relatively thin, it has high surface hardness and curls. It is possible to obtain an antiglare hard coat film that is less likely to occur.

Further, in forming the antiglare hard coat film of the present invention, it is preferable that the silica particles are crushed silica particles.
This is because such crushed silica particles tend to have a wider particle size distribution than spherical silica particles, and tend to effectively enhance mutual adhesion with other materials.
Therefore, crushed silica particles having a relatively large average particle size are likely to be present, and a part of the crushed silica particles is likely to stably protrude from the surface of the antiglare hard coat layer, and has a higher surface hardness. This is because it is possible to obtain an antiglare hard coat film with less curling.

Further, in constructing the antiglare hard coat film of the present invention, the overall haze value of the antiglare hard coat film measured in accordance with JIS K 7136 (2000) is set to a value within the range of 15 to 40%. It is preferable that the internal haze value is in the range of 5 to 38% and the external haze value is less than 40%.
By controlling not only the overall haze value of the antiglare hard coat layer but also the external haze value in this way, it is possible to more effectively prevent white browning, and further excellent antiglare, image visibility, and glare. Inhibitory properties can be obtained.

Further, in constructing the antiglare hard coat film of the present invention, it is preferable that the surface hardness of the antiglare hard coat layer is 2H or more.
By controlling the surface hardness in this way, even if the thickness of the antiglare hardcoat layer is relatively thin, the antiglare hardcoat film stably provided with the antiglare hardcoat layer having a higher surface hardness. Can be obtained.

Another aspect of the present invention is a method for producing an antiglare hardcoat film provided with an antiglare hardcoat layer on the surface (particularly one side) of a plastic base material, at least from step (1) to step (1). This is a method for producing an antiglare hard coat film, which comprises (3).
(1) 5 to 5 silica particles having an average particle size in the range of 2.1 to 10 μm as the component (B1) with respect to 100 parts by mass of the active energy ray-curable resin as the component (A). High refractive index particles having 25 parts by mass and an average particle size as a component (B2) in the range of 1 to 500 nm, and high refractive index as inorganic fine particles having a refractive index of 1.8 or more. and the particles 3 to 30 parts by weight, (B3) as a component, the resin particles to a value within the range of the average particle size 0.5~2μm in proportions of 4 to 25 parts by weight, antiglare hard Step of using the coating layer forming material (2) Step of applying the antiglare hard coat layer forming material on the base material to form a coating film (3) Activity with respect to the coating film on the base material A step of irradiating energy rays to form an antiglare hardcoat layer having a thickness of 8 μm or less, in which silica particles protrude from the surface of the antiglare hardcoat layer opposite to the plastic substrate.
By forming the antiglare hard coat film containing at least three kinds of particles (B1 to B3) in a predetermined ratio in this way, silica is formed from the predetermined surface of the antiglare hard coat layer (film-like cured product). The particles can be reliably and stably projected.
Further, by using the high refractive index particles whose average particle size is controlled in this way, it is possible to more effectively prevent the white browning property in combination with the predetermined silica particles and resin particles, and also to have more excellent antiglare property. Etc. can be obtained.
Therefore, it is possible to effectively prevent white-browning, and it has excellent anti-glare properties. Furthermore, even if the anti-glare hard coat layer is relatively thin, it has high surface hardness and curls occur. It is possible to efficiently obtain an antiglare hard coat film with less.

1 (a) to 1 (b) are views provided for comparing and explaining aspects of the antiglare hard coat film of the present invention and conventional antiglare hard coat films. FIG. 2A is a diagram provided for explaining the particle size distribution chart of the silica particles used in Example 1 and the like, and FIG. 2B is a diagram provided for explaining another particle size distribution chart of the silica particles. 2 (c) is a diagram provided for explaining the particle size distribution chart of the resin particles used in Example 1 and the like. FIG. 3 is a diagram provided for explaining an embodiment of a polarizing plate made of the antiglare hard coat film of the present invention. 4 (a) to 4 (b) are diagrams provided for explaining the image visibility in Example 1 and Comparative Example 1, respectively.

[First Embodiment]
The first embodiment is an antiglare hard coat film having an antiglare hardcoat layer on the surface of a plastic base material, wherein the antiglare hardcoat layer is formed.
(A) With respect to 100 parts by mass of active energy ray-curable resin as a component
(B1) Silica particles as a component were added to 5 to 25 parts by mass.
(B2) High-refractive index particles as a component of 3 to 30 parts by mass,
(B3) Resin particles as a component, 4 to 25 parts by mass,
An antiglare hardcoat layer having a thickness of 8 μm or less, which is derived from a material for forming an antiglare hardcoat layer, and from the surface of the antiglare hardcoat layer opposite to the plastic substrate. It is an antiglare hard coat film characterized by protruding silica particles.
Hereinafter, the first embodiment of the present invention will be specifically described with reference to the drawings as appropriate. For example, FIG. 1A is a diagram provided for explaining a cross section of the antiglare hard coat film 10 of the first embodiment, and FIG. 1B is a conventional antiglare hard coat film. It is a figure provided for demonstrating the cross section of 10'.

1. 1. Anti-glare hard coat layer (1) Anti-glare hard coat layer forming material As shown in FIG. 1 (a), the anti-glare hard coat film 10 of the present invention has a plurality of predetermined particles on a plastic base material 12. It contains an antiglare hard coat layer (sometimes referred to as a film-like cured product) 16 comprising 14 (14a, 14b, 14c).
That is, as shown in the cross section in FIG. 1A, the antiglare hard coat layer 16 typically contains the active energy ray-curable resin 15 as the component (A) and the component (B1). Forming an antiglare hard coat layer containing silica particles 14a, high refractive index particles 14b as a component (B2), resin particles 14c as a component (B3), and a photopolymerization initiator as a component (C). It is composed of a film-like cured product of the material.

On the other hand, as shown in the cross section in FIG. 1B, a typical conventional antiglare hard coat film 10'contains spherical resin particles 14'on a plastic base material 12'. The sex hard coat layer 16'is provided.
That is, for example, only relatively large spherical resin particles 14'are used as the particles for imparting antiglare property based on light scattering or the like to the antiglare hard coat layer 16', and Comparative Example 13 of the present invention is used. The configurations shown in ~ 17 correspond to each other.

(1) -1 (A) component: active energy ray-curable resin The type of the active energy ray-curable resin (including the ultraviolet curable resin) as the component (A) is not particularly limited. Conventionally known ones can be selected, and examples thereof include energy ray-curable monomers, oligomers, resins, and mixtures thereof.
More specifically, it is preferable to use a polyfunctional (meth) acrylic monomer or a (meth) acrylate-based prepolymer.

Examples of the polyfunctional (meth) acrylic monomer include 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, and polyethylene. Glycoldi (meth) acrylate, neopentyl glycol di (meth) acrylate of hydroxypivalate, dicyclopentanyldi (meth) acrylate, caprolactone-modified dicyclopentenyldi (meth) acrylate, ethylene oxide-modified di (meth) acrylate of phosphate, Allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethylolpropanthry (meth) acrylate, dipentaerythritol tri (meth) acrylate, propionic acid-modified dipentaerythritol tri (meth) acrylate, pentaerythritol tri (Meta) acrylate, propylene oxide modified trimethylol propantri (meth) acrylate, tris (acryloxyethyl) isocyanurate, propionic acid modified dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, caprolactone modified di Examples thereof include polyfunctional (meth) acrylates such as pentaerythritol hexa (meth) acrylates.
Further, these monomers may be used alone or in combination of two or more.

Examples of the (meth) acrylate-based prepolymer include polyester acrylate-based, epoxy acrylate-based, urethane acrylate-based, and polyol acrylate-based.
Here, as the polyester acrylate-based prepolymer, for example, by esterifying the hydroxyl groups of a polyester oligomer having hydroxyl groups at both ends obtained by condensation of a polyvalent carboxylic acid and a polyhydric alcohol with (meth) acrylic acid, or , It can be obtained by esterifying the hydroxyl group at the terminal of the oligomer obtained by adding an alkylene oxide to a polyvalent carboxylic acid with (meth) acrylic acid.
Further, the epoxy acrylate-based prepolymer can be obtained, for example, by reacting (meth) acrylic acid with the oxylan ring of a bisphenol type epoxy resin or a novolak type epoxy resin having a relatively low molecular weight to esterify it.
Further, the urethane acrylate-based prepolymer can be obtained, for example, by esterifying a polyurethane oligomer obtained by a reaction between a polyether polyol or a polyester polyol and a polyisocyanate with (meth) acrylic acid.
Further, the polyol acrylate-based prepolymer can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid. These prepolymers may be used alone, in combination of two or more, or in combination with the above-mentioned polyfunctional (meth) acrylate-based monomer.

(1) -2 (B) component: Multiple types of particles (i) (B1) component (silica particles)
(type)
The silica particles as the component (B1) are larger than the average particle size (φ2) of the high refractive index particles as the component (B2) and the average particle size (φ3) of the resin particles as the component (B3). It has a diameter (φ1), and in its particle size distribution, particles having a particle size larger than the film thickness (t) of the antiglare hard coat layer are distributed, and it is considerably hard (for example,). , Vickers hardness is 1200 MPa or more).
Therefore, since a part of the silica particles protrudes to the surface side of the antiglare hard coat layer opposite to the plastic base material, it is possible to effectively prevent whitening and excellent antiglare. Further, even if the antiglare hard coat layer is relatively thin, it can be an antiglare hard coat film having high surface hardness and less curling.

Here, examples of the type of silica particles as the component (B1) include one type alone, such as spherical silica and amorphous crushed silica, or a combination of two or more types.
The silica particles are more preferably pulverized silica particles.
The reason for this is that the crushed silica particles tend to have a wider particle size distribution than the spherical silica particles, and the crushed silica particles are larger and smaller than the average particle size than the spherical silica particles. This is because the abundance ratio of the particles is high.
When the abundance ratio of particles larger than the average particle size increases, a part of the particles tends to stably protrude from the surface of the antiglare hard coat layer, effectively preventing white-browning and excellent prevention. Can develop glare.
On the other hand, when the abundance ratio of particles smaller than the average particle size increases, the abundance ratio of silica particles in the antiglare hard coat layer increases, and an antiglare hard coat layer having high surface hardness can be obtained.
Further, since the surface of the crushed silica particles has many fine irregularities (corners and protrusions), the surface area of the crushed silica particles is larger than that of the spherical silica particles and the like, so that the contact area with other materials is large.
As a result, the adhesion between the crushed silica particles and other materials is effectively enhanced, and the antiglare hardcoat has a higher surface hardness even if the antiglare hardcoat layer is relatively thin. Layers can be obtained.
Therefore, by using the crushed silica particles, as described above, due to the characteristics such as the particle size distribution of the particles, the white-brownness is effectively prevented, and excellent anti-glare property is exhibited and high. An antiglare hard coat film having a surface hardness can be obtained.
The crushed silica particles are silica particles obtained by crushing spherical silica such as molten silica or crystalline silica by a predetermined means, and are usually silica particles having irregularities such as sharp corners and protrusions on the surface. means.

(Average particle size)
The average particle size (φ1: volume average particle size) of the silica particles as the component (B1) contained in the antiglare hard coat layer forming material is usually set to a value within the range of 2.1 to 10 μm. preferable.
When the average particle size of the silica particles is within such a range, it is possible to easily adjust the external haze value and the like, effectively prevent white-brownness, and exhibit excellent antiglare properties. This makes it possible to effectively suppress the occurrence of glare while maintaining image visibility. Further, when the average particle size of the silica particles is within such a range, the thickness of the antiglare hard coat layer can be made relatively thin, and while having a high surface hardness, the carr It is possible to obtain an antiglare hard coat film having an antiglare hard coat layer with less generation of silica.
More specifically, when the average particle size of the silica particles is less than 2.1 μm, it becomes difficult for the silica particles to protrude from the surface of the antiglare hard coat layer, and it becomes difficult to adjust the value such as the external haze value. As a result, it may be difficult to maintain sufficient anti-glare properties and anti-glare properties.
On the other hand, if the average particle size of the silica particles exceeds 10 μm, it becomes difficult to prevent white-brownness and ensure image visibility, especially when applied to a high-definition display, and further, the surface hardness decreases and curls occur. Etc. may easily occur.
Therefore, the average particle size of the silica particles is more preferably set to a value in the range of 2.5 to 8 μm, and further preferably set to a value in the range of 3 to 6 μm.

The average particle size (φ1) of the silica particles is preferably determined in consideration of the film thickness (t) of the hard coat layer, and further, the average particle size of the silica particles and the film thickness of the hard coat layer are approximately equal to each other. It is preferable that they are equivalent.
The reason is that if the average particle size of the silica particles and the film thickness of the hard coat layer are substantially the same, a part of the silica particles is uniformly and stably projected from the surface of the antiglare hard coat layer. Because it can be done.
For example, by satisfying the relational expression of 0.8 × t ≦ φ1 ≦ 2.0 × t, more preferably by satisfying the relational expression of 0.9 × t ≦ φ1 ≦ 1.8 × t. A part of the silica particles easily protrudes to the surface side of the antiglare hard coat layer opposite to the plastic base material, and it becomes easy to effectively adjust the external haze value and the like.
As a result, it is possible to effectively prevent white-brownness and to exhibit excellent anti-glare property, and it is possible to obtain a hard coat layer in which glare is suppressed while ensuring image visibility.

Further, referring to the particle size distribution of the silica particles as the component (B1), it is preferable to have the particle size distribution chart shown in FIGS. 2 (a) and 2 (b).
That is, the particle size distribution chart of the silica particles shown in FIG. 2A corresponds to the silica particles used in Example 1 and the like, but has two peaks on the particle size distribution chart, and two or more types. It is understood that silica particles having different particle size distributions are mixed.
That is, it is a combination silica particle (average particle size: 3.2 μm) of a first silica particle having an average particle size of about 8 μm and a second silica particle having an average particle size of about 0.7 μm.
On the other hand, the particle size distribution chart of the silica particles shown in FIG. 2B is characterized by having one peak on the particle size distribution chart. That is, it is understood that the silica particles have an average particle size of about 3 μm (average particle size: 3.2 μm).
Then, in the case of Example 1 and the like of the present invention, although the combined silica particles having the particle size distribution shown in FIG. 2 (a) are used, the single silica particles having the particle size distribution shown in FIG. 2 (b) are used. However, it has been separately confirmed that it exhibits the same anti-glare property and anti-glare property.

(Mixing amount)
Further, the blending amount of silica particles as the component (B1) contained in the antiglare hard coat layer forming material is set to a value within the range of 5 to 25 parts by mass with respect to 100 parts by mass of the component (A). Is preferable.
When the blending amount of the silica particles is within such a range, it is possible to easily adjust the external haze value and the like, effectively prevent white browning, and exhibit excellent antiglare. Furthermore, it is possible to effectively suppress the occurrence of glare while maintaining the image visibility.
More specifically, when the blending amount of the silica particles is less than 5 parts by mass, a part of the silica particles is less likely to protrude from the surface of the antiglare hard coat layer, and the value of the external haze value or the like becomes Adjustment becomes difficult. Therefore, it may be difficult to develop sufficient antiglare properties, or it may be difficult to suppress the occurrence of glare.
On the other hand, if the blending amount of the silica particles exceeds 25 parts by mass, it may be difficult to prevent white-brownness or ensure image visibility, or the surface hardness may be reduced, especially when applied to a high-definition display. It may decrease.
Therefore, the blending amount of the silica particles is more preferably set to a value in the range of 7 to 20 parts by mass, and set to a value in the range of 10 to 15 parts by mass with respect to 100 parts by mass of the component (A). Is even more preferable.

(Ii) (B2) component: High refractive index particles (type)
The high refractive index particles as the component (B2) _{correspond to, for example, inorganic fine particles having a refractive index (nd} ) of 1.8 or more, but more preferably an refractive index ( _nd ) of 1.9 or more. Some inorganic fine particles, more preferably inorganic fine particles having a refractive index ( _nd ) of 2.0 or more.
Specifically, the zirconium oxide particles _(n d: 2.1), titanium oxide particles _(n d: 2.5 to 2.7), chromium oxide _(trivalent) (n d: _2.5), copper oxide _(n d: 2.7), zinc oxide _(n d: 2.0), platinum _(n d: 2.95), tungsten _(n d: 2.76) at least one can be cited, such as, in particular, Zirconium oxide particles are preferred.
The reason for this is that if the high-refractive index particles are zirconium oxide particles, they are relatively large with respect to the component specific gravity of the antiglare hard coat layer and the average particle size is small. It is unevenly distributed on the bottom, that is, on the plastic substrate side of the antiglare hard coat layer, and can effectively exert an adjustment function such as an internal haze value.
Further, since the zirconium oxide particles tend to collect around the relatively large silica particles as the component (B1), the fixation and surface hardness of the silica particles are only improved by blending the zirconium oxide particles. Alternatively, the surface hardness caused by the silica particles can be more effectively exhibited.
Here, as the type of zirconium oxide particles as the component (B2), for example, _{a compound represented by ZrO 2} is applicable as the main component, and it is preferable that the zirconium oxide particles have a monoclinic crystal structure at room temperature.
As the zirconium oxide particles, stabilized zirconium oxide particles obtained by blending zirconium with a rare earth oxide such as calcium oxide, magnesium oxide, or yttrium oxide, or similar semi-stabilized zirconium oxide particles can also be used. ..

The surface of the zirconium oxide particles has a radical reactive group so as to prevent the zirconium oxide particles from aggregating and being excessively unevenly distributed and to be firmly fixed inside the antiglare hard coat layer. It is preferable to use reactive zirconium oxide particles which are mixed and coated with monomers, oligomers and the like.
Therefore, such reactive zirconium oxide particles further gather around the relatively large silica particles to form a strong inorganic region, so that the effect of further increasing the surface hardness of the antiglare hard coat layer is also exhibited. can do.

(Average particle size)
In the present invention, the average particle size (φ2: volume average particle size) of the high-refractive index particles as the component (B2) is preferably set to a value within the range of 1 to 1000 nm.
The reason for this is that if the average particle size of the high-refractive index particles is within such a range, it becomes easy to adjust the internal haze value and the like, and the glare is maintained while maintaining excellent antiglare and image visibility. This is because the occurrence of the above can be effectively suppressed.
If the average particle size of the high-refractive index particles is less than 1 nm, it may be difficult to maintain sufficient antiglare properties.
On the other hand, if the average particle size of the high-refractive index particles exceeds 1000 nm, it may be difficult to effectively suppress the occurrence of glare, particularly when applied to a high-definition display.
Therefore, the average particle size of the high-refractive index particles is more preferably set to a value in the range of 5 to 500 nm, and further preferably set to a value in the range of 10 to 100 nm.
For the average particle size (volume average particle size) of high refractive index particles, for example, a volume-based particle size distribution chart is created using a laser diffraction / scattering type particle size distribution measuring device, and the median diameter is based on the chart. It can be measured as D50 of.

(Mixing amount)
The blending amount of the high refractive index particles as the component (B2) is preferably set to a value within the range of 3 to 30 parts by mass with respect to 100 parts by mass of the component (A).
The reason for this is that when the blending amount of the high-refractive index particles is within such a range, it becomes easy to adjust the internal haze value and the like, and therefore, the glare is maintained while maintaining excellent antiglare and image visibility. This is because the occurrence of the above can be effectively suppressed.
That is, when the blending amount of the high refractive index particles is less than 3 parts by mass, it may be difficult to adjust the internal haze value or the like, and it may be difficult to exhibit sufficient antiglare properties.
On the other hand, if the blending amount of the high-refractive index particles exceeds 30 parts by mass, it may be difficult to suppress the occurrence of glare and ensure image visibility, especially when applied to a high-definition display.
Therefore, the blending amount of the high refractive index particles is more preferably set to a value in the range of 5 to 28 parts by mass, further preferably set to a value in the range of 8 to 25 parts by mass, and 10 to 20 parts by mass. Most preferably, the value is within the range.

(Iii) (B3) component: Resin particles Since the resin particles as the (B3) component are relatively small with respect to the film thickness (t) of the antiglare hardcoat layer, they are on the surface of the antiglare hardcoat layer. However, in combination with the high refractive index particles which are abundantly present inside and are the component (B2), it is possible to further facilitate the adjustment of the internal haze value and the like of the antiglare hard coat layer of the present invention.
The reason for this is that the structure in which the refractive index differs in the antiglare hard coat layer due to the presence of the portion where the resin particles as the component (B3) are present and the portion where the high refractive index particles which are the component (B2) are present. As a result, it becomes easy to adjust the internal haze value and the like.

Here, examples of the type of resin particles as the component (B3) include silicone resin fine particles, modified silicone resin fine particles, melamine resin fine particles, and acrylic polymer resin fine particles (for example, polymethylmethacrylate resin fine particles and the like). , Acrylic-styrene copolymer resin fine particles, polycarbonate resin fine particles, polyethylene resin fine particles, styrene polymer resin fine particles, benzoguanamine resin fine particles, etc., are preferably used alone or in admixture of two or more.
Above all, at least one selected from the group consisting of acrylic polymer resin fine particles, acrylic-styrene copolymer resin fine particles, styrene polymer resin fine particles and silicone resin fine particles is preferable.
The reason for this is that while these resin fine particles are relatively inexpensive, they contribute to the dispersibility of the silica particles as the component (B1) and the high refractive index particles as the component (B2), and are hard to prevent glare. This contributes to the stable formation of fine irregularities caused by the component (B1) on the surface of the coat layer, and in combination with the component (B2), it becomes easy to obtain a desired internal haze value or the like. Is.
Further, in relation to the component (B1), when the antiglare hard coat layer forming material is applied to the surface of the plastic base material, the antiglare hard of the silica particles as the component (B1) in the coating film. The degree of protrusion from the surface of the coat layer can be effectively controlled, and fine irregularities on the surface of the antiglare hard coat layer can be formed more stably.
As a result, it is possible to effectively prevent white-brownness and to exhibit excellent anti-glare property, and in combination with the above-mentioned ease of adjusting the internal haze value, etc., while ensuring image visibility. , An antiglare hard coat layer that suppresses the occurrence of glare can be obtained.

(Average particle size)
The average particle size (volume average particle size) of the resin particles as the component (B3) is preferably set to a value within the range of 0.5 to 2 μm.
The reason for this is that when the average particle size of the resin particles is within such a range, the internal haze can be easily adjusted, and glare occurs while maintaining excellent antiglare and image visibility. This is because it can be effectively suppressed.
If the average particle size of the resin particles is less than 0.5 μm, it may be difficult to suppress the occurrence of glare.
On the other hand, if the average particle size of the resin particles exceeds 2 μm, it may be difficult to ensure image visibility, especially when applied to a high-definition display.
Therefore, the average particle size of the resin particles is more preferably set to a value in the range of 0.8 to 1.8 μm, and further preferably set to a value in the range of 1.0 to 1.6 μm.
For the average particle size of the resin particles, for example, a laser diffraction / scattering type particle size distribution measuring device is used to obtain a volume-based particle size distribution chart as shown in FIG. 2C, and then D50 as the median diameter is obtained. Can be calculated as.

(Mixing amount)
The blending amount of the resin particles as the component (B3) is preferably set to a value within the range of 4 to 25 parts by mass with respect to 100 parts by mass of the component (A).
The reason for this is to ensure image visibility by allowing relatively small resin particles to exist inside the antiglare hard coat layer and expressing a predetermined internal haze value, and (B1). This is to obtain excellent antiglare property by stably forming fine irregularities caused by silica particles as a component.
More specifically, when the blending amount of the resin particles is less than 4 parts by mass, fine irregularities cannot be sufficiently formed on the surface of the antiglare hard coat layer, and the desired antiglare property is obtained. Can be difficult.
On the other hand, when the blending amount of the resin particles exceeds 25 parts by mass, the haze value becomes excessively large, and the image visibility of the display image on the display may decrease.
Therefore, the blending amount of the resin fine particles is more preferably set to a value in the range of 8 to 23 parts by mass with respect to 100 parts by mass of the active energy ray-curable resin as the component (A), and 10 to 20 parts by mass. The value is more preferably in the range of 12 to 18 parts by mass, and further preferably in the range of 12 to 18 parts by mass.

(1) -4 (C) component: Photopolymerization initiator (i) type The antiglare hard coat layer forming material is prepared by reacting an active energy ray-curable resin as the component (A) easily and in a short time. In order to cure, it is preferable to further contain a photopolymerization initiator as the component (C).
Examples of such photopolymerization initiators include benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin-n-butyl ether, benzoin isobutyl ether, acetophenone, dimethylaminoacetophenone, and 2,2-dimethoxy-. 2-Phenylacetophenone, 2,2-diethoxy-2-phenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexylphenylketone, 2-methyl-1- [4-( Methylthio) phenyl] -2-morpholino-propan-1-one, 4- (2-hydroxyethoxy) phenyl-2 (hydroxy-2-propyl) ketone, benzophenone, p-phenylbenzophenone, 4,4'-diethylaminobenzophenone, Dichlorobenzophenone, 2-methylanthraquinone, 2-ethylanthraquinone, 2-terriary butyl anthraquinone, 2-aminoanthraquinone, 2-methylthioxanthone, 2-ethylthioxanthone, 2-chlorothioxanthone, 2,4-dimethylthioxanthone, 2,4 -Diethylthioxanthone, benzyl dimethyl ketal, acetophenone dimethyl ketal, p-dimethylaminobenzoic acid ester, etc. may be used alone or in combination of two or more.

(Ii) Blending amount The blending amount of the photopolymerization initiator as the component (C) is usually in the range of 0.2 to 10 parts by mass with respect to 100 parts by mass of the active energy ray-curable resin as the component (A). It is preferable to set the value within.
The reason for this is that if the blending amount of the photopolymerization initiator is less than 0.2 parts by mass, it may be difficult to obtain sufficient curability.
On the other hand, if the blending amount of the photopolymerization initiator exceeds 10 parts by mass, the scratch resistance may decrease.
Therefore, it is more preferable that the blending amount of the photopolymerization initiator is in the range of 0.5 to 7 parts by mass with respect to 100 parts by mass of the active energy ray-curable resin as the component (A). It is more preferable that the value is in the range of ~ 5 parts by mass.

(1) -5 Additives, etc. The antiglare hard coat layer forming material is prepared by appropriately adding the above-mentioned components (A) to (C) in an appropriate solvent and uniformly dissolving or dispersing them. Can be prepared.
At this time, in addition to the components (A) to (C), as additives, for example, an antioxidant, an ultraviolet absorber, a silane coupling agent, a light stabilizer, a leveling agent, a defoaming agent, a dispersant, etc. It is also preferable to further add at least one such as a slip agent.
Examples of the solvent used include aliphatic hydrocarbons such as hexane and heptane, aromatic hydrocarbons such as toluene and xylene, halogenated hydrocarbons such as methylene chloride and ethylene chloride, methanol, ethanol, propanol and butanol. Examples thereof include ketones such as alcohol, acetone, methyl ethyl ketone, 2-pentanone, isophorone and cyclohexanone, esters such as ethyl acetate and butyl acetate, and cellosolve solvents such as ethyl cellosolve.
The concentration and viscosity of the antiglare hard coat layer forming material prepared in this manner may be within a numerical range that can be coated on the surface of the plastic base material, and can be appropriately selected depending on the situation. ..

(2) Thickness The thickness (t) of the antiglare hard coat layer is characterized by having a value of 8 μm or less.
The reason for this is that when the thickness of the antiglare hardcoat layer exceeds 8 μm, the desired structure in the antiglare hardcoat layer cannot be obtained, or the active energy ray-curable resin is cured and shrunk. This is because it may be difficult to suppress curl due to the above, or it may be difficult to suppress cracks in the antiglare hardcoat layer generated when the antiglare hardcoat film is bent.
However, if the thickness of the antiglare hard coat layer becomes excessively thin, it may be difficult to obtain the surface hardness required for actual use.
Therefore, the thickness of the antiglare hard coat layer is more preferably set to a value in the range of 1 to 7 μm, further preferably set to a value in the range of 2 to 6 μm, and a value in the range of 3 to 5 μm. Is most preferable.

2. Plastic base material As the type of plastic base material, a plastic base material known as a transparent base material of a conventionally hard-coated film for optics can be appropriately selected and used.
Therefore, for example, polyester films such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate, polyethylene films, polypropylene films, cellophane, diacetyl cellulose, triacetyl cellulose, acetyl cellulose butyrate, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, etc. Ethylene-vinyl acetate copolymer, polystyrene, polycarbonate, polymethylpentene, polysulfone, polyether ether ketone, polyether sulfone, polyetherimide, polyimide, fluororesin, polyamide, acrylic resin, norbornene resin, cycloolefin resin, etc. Can be mentioned.
In particular, the plastic substrate is preferably triacetyl cellulose (TAC).
The reason for this is that TAC has low optical anisotropy, high transparency, and is less likely to cause blurring of image display, and is relatively inexpensive and economical. Is.
From the viewpoint of good handleability, the film thickness of the plastic base material is preferably set to a value within the range of 15 to 300 μm, more preferably set to a value within the range of 30 to 200 μm, and 50 to 100 μm. It is more preferable that the value is within the range of.

Further, as shown in FIG. 3, the antiglare hard coat film 110 of the present invention can be bonded to the polarizer 111 to form a polarizing plate 120.
That is, as the plastic base material, for example, a film having less optical anisotropy such as a triacetyl cellulose (TAC) film (first TAC film) 112a is used, and an antiglare hard coat layer 116 is used on one surface thereof. The antiglare hard coat film 110 is prepared.
Next, the first TAC film 112a on which the antiglare hard coat layer 116 is formed is laminated on one side of the polarizer 111, for example, a polyvinyl alcohol-based polarizer, via the first adhesive layer 115a.
On the other hand, the second TAC film 112b is laminated via the second adhesive layer 115b on the other opposite surface of the polarizer 111, on the side on which the antiglare hard coat layer 116 is not formed. ..
As a result, it is possible to obtain a polarizing plate 120 having excellent antiglare properties and capable of effectively suppressing the occurrence of glare even when applied to a high-definition display.
As shown in FIG. 3, it is also preferable that the polarizing plate 120 is provided with an adhesive layer 118 or a release sheet 119 for bonding to an optical component such as a liquid crystal cell.

3. 3. Characteristics of anti-glare hard coat film (1) Haze value (overall haze value)
Further, the overall haze value (sometimes simply referred to as the haze value) of the antiglare hard coat film measured in accordance with JIS K 7136 (2000) shall be a value within the range of 15 to 40%. Is preferable.
The reason for this is that if the overall haze value is less than 15%, it may be difficult to obtain excellent glare suppression properties.
On the other hand, if the overall haze value exceeds 40%, the white-brownness of the display may be remarkably generated or the image visibility may be remarkably lowered.
Therefore, the overall haze value of the antiglare hard coat film is more preferably set to a value in the range of 18 to 35%, and further preferably set to a value in the range of 20 to 33%.

(Internal haze value)
The internal haze value of the antiglare hard coat layer is preferably set to a value in the range of 5% to 38%.
When the internal haze value is less than 5%, the white tea property, glare, and anti-glare property may be lowered.
On the other hand, if the internal haze value exceeds 38%, the image visibility may be significantly reduced.
Therefore, the internal haze value of the antiglare hard coat film is more preferably set to a value in the range of 6 to 30%, and further preferably set to a value in the range of 8 to 25%.

(External haze value)
The external haze value of the antiglare hard coat layer is preferably a value of less than 40%.
When the external haze value is 40% or more, the display may be significantly browned.
However, if the external haze value becomes excessively low, the glare or anti-glare property may decrease.
Therefore, the external haze value of the antiglare hard coat film is more preferably set to a value in the range of 6 to 35%, and further preferably set to a value in the range of 8 to 25%.

(2) Surface hardness It is preferable that the antiglare hard coat film has a predetermined surface hardness as a pencil hardness and does not change its appearance in the evaluation of scratch resistance using steel wool.
The reason for this is that if the surface hardness is excessively low, a change in appearance is observed in the evaluation of the scratch resistance, and it may be difficult to obtain sufficient scratch resistance as a hard coat film.
Therefore, the antiglare hard coat film preferably has a surface hardness (pencil hardness) of 1H or more, and more preferably 2H or more.
The reason for this is that by limiting the surface hardness of the antiglare hardcoat layer in this way, an antiglare hardcoat having an antiglare hardcoat layer having better scratch resistance even if it is relatively thin. This is because a film can be obtained.

(3) Surface roughness 1
In addition, the arithmetic mean roughness (Ra), which is one of the indexes of the surface roughness of the antiglare hard coat film measured in accordance with JIS B 0601 (2001), is within the range of 0.1 to 0.3 nm. It is preferable to set the value to.
The reason for this is that if the Ra is less than 0.1 nm, it may be difficult to obtain excellent antiglare properties.
On the other hand, when the Ra exceeds 0.3 nm, the white-brownness may be significantly reduced.
Therefore, it is more preferable to set such Ra to a value in the range of 0.15 to 0.28, and further preferably to set it to a value in the range of 0.2 to 0.25.

(4) Surface roughness 2
Further, the maximum cross-sectional height (Rt), which is one of the indexes of the surface roughness of the antiglare hard coat film measured in accordance with JIS B 0601 (2001), is a value within the range of 1 to 4.5 nm. Is preferable.
The reason for this is that if the Rt is less than 1 nm, it may be difficult to obtain excellent antiglare properties.
On the other hand, when the Ra exceeds 4.5 nm, the white tea property may be significantly reduced.
Therefore, the surface roughness (Rt) of the antiglare hard coat film is more preferably set to a value in the range of 1.5 to 4 nm, and further preferably set to a value in the range of 2 to 3 nm.

[Second Embodiment]
The second embodiment is a method for producing an antiglare hard coat film having an antiglare hardcoat layer on the surface of a plastic base material, and includes at least steps (1) to (3). This is a method for producing an antiglare hard coat film.
(1) With respect to 100 parts by mass of the active energy ray-curable resin as the component (A), 5 to 25 parts by mass of silica particles as the component (B1) and 3 high refractive index particles as the component (B2). Step of blending ~ 30 parts by mass and resin particles as (B3) component in a ratio of 4 to 25 parts by mass to form an antiglare hard coat layer forming material (2) Antiglare hard coat layer forming material. Step of coating on a base material to form a coating film (3) The coating film on the base material is irradiated with active energy rays to form an antiglare hardcoat layer. A step of forming an antiglare hard coat layer having a thickness of 8 μm or less, in which silica particles protrude from the surface of the layer opposite to the plastic base material.

1. 1. Manufacturing process of antiglare hard coat layer forming material With respect to 100 parts by mass of active energy ray-curable resin as component (A), 5 to 25 parts by mass of silica particles as component (B1) and component (B2) This is a manufacturing process in which 3 to 30 parts by mass of high-refractive-index particles and 4 to 25 parts by mass of resin particles as the component (B3) are blended to prepare an antiglare hard coat layer forming material.
That is, a predetermined amount of the component (A), the component (B1), the component (B2), and the component (B3) are uniformly mixed using a known mixing device to obtain an antiglare hard coat layer forming material. It is a process.
In addition, in order to mix and stir the compounded components uniformly and in a short time, at least one of a propeller mixer, a ball mill, a bead mill, a V blender, a triple roll, a kneader, a planetary mixer, a jet mill and the like is used as a known mixing device. Is preferable.

2. Step of forming a coating film with an antiglare hard coat layer forming material Next, a coating film with an antiglare hard coat layer forming material is formed.
That is, as a step of forming a coating film, a conventionally known laminating method, for example, a bar coating method, a knife coating method, a roll coating method, a blade coating method, is applied on the surface of a plastic base material with an antiglare hard coat layer forming material. This is a step of forming a coating film by coating using a die coating method, a gravure coating method, or the like.

3. 3. Coating film curing step Next, a coating film curing step is carried out.
That is, after the coating film is dried, the coating film is cured by irradiating it with active energy rays to form the coating film into an antiglare hardcoat layer having a predetermined thickness to obtain an antiglare hardcoat film. Can be done.
Here, ultraviolet rays are mentioned as active energy rays when curing the coating film, and such ultraviolet rays can be irradiated by a high-pressure mercury lamp, an electrodeless lamp, a metal halide lamp, a xenon lamp, or the like.
As the irradiation amount of the ultraviolet, usually, preferably a value within the range of 100 to 500 mJ / cm ^2, and more preferably a value within a range of 150~400mJ / cm ^2.

Hereinafter, the antiglare hard coat film of the present invention will be described in more detail with reference to Examples.

[Example 1]
1. 1. Production of anti-glare hard coat film (1) Preparation step of anti-glare hard coat layer forming material (A) 50 parts by mass of ultraviolet curable resin (multi-purpose acrylate-based monomer and 50 parts by mass of urethane acrylate oligomer) as components With respect to 100 parts by mass of the mixture), 7 parts by mass of crushed silica particles (average particle size: 3.2 μm, refractive index: 1.5) as the component (B1) and reactive zirconium oxide as the component (B2) 10 parts by mass of particles (manufactured by Solar Co., Ltd., ZR-020, average particle size: 50 nm, refractive index: 2.1) and acrylic resin particles as component (B3) (manufactured by Sekisui Kasei Kogyo Co., Ltd., Mix 15 parts by mass of XX-27LA, average particle size: 1.5 μm, refractive index: 1.5) and 2 parts by mass of a photopolymerization initiator (BASF, OMNIRAD184) which is a component (C). At the same time, it was diluted with propylene glycol monomethyl ether to produce an antiglare hard coat layer forming material having a solid content of 30% by mass.
The parts by mass of the components (B1) to (B3) in Table 1 are the blending ratio with respect to 100 parts by mass of the component (A).

(2) Coating Step Next, the obtained antiglare hard coat layer forming material is used as an easy-adhesive agent for a triacetyl cellulose film (manufactured by TACBRIGHT, TECPHANP980RO, film thickness: 80 μm) with an easy-adhesive layer as a plastic base material. The layer was coated with a wire bar # 14 so that the film thickness after curing was 3.5 μm to form a predetermined coating film.

(3) Drying Step Next, the obtained coating film was dried at 70 ° C. for 1 minute using a hot air drying device.

(4) Curing Step Next, the dried coating film is irradiated with ultraviolet rays under the following conditions using an ultraviolet irradiation device (manufactured by GS Yuasa Corporation, light source: high-pressure mercury lamp) to cure the coating film. Then, an antiglare hard coat layer as a film-like cured product was formed, and a final antiglare hard coat film was obtained.
Illuminance: 100mW / cm ²
Light intensity: 240mJ / cm ²

2. Evaluation of anti-glare hard coat film (1) Evaluation 1 (surface roughness)
The surface roughness (Ra and Rt) of the obtained antiglare hard coat film was measured using a surface roughness meter (manufactured by Mitutoyo, SV-3000) in accordance with JIS B 0601 (2001).

(2) Evaluation 2 (haze value)
In accordance with JIS K 7136 (2000), the haze value (%) of the obtained antiglare hard coat film was measured using a haze meter (NDH5000 manufactured by Nippon Denshoku Kogyo Co., Ltd.), and the haze value (%) was measured. The total haze value (%) was used.
Next, the release film on one side of the transparent optical adhesive (OPTERIA NO-T015 manufactured by Lintec Co., Ltd.), which is a double-sided adhesive, is peeled off to prevent the exposed surface from being covered with an antiglare hard coat film. After aligning the glare hard coat layers so as to face each other, an antiglare hard coat film was attached.
The haze value was measured with the release film on the other side of the transparent optical adhesive material peeled off, and used as the internal haze value (%) of the antiglare hard coat film.
Further, the internal haze value (%) was subtracted from the total haze value (%), and this was used as the external haze value (%) of the antiglare hard coat film.

(3) Evaluation 3 (white tea)
The obtained anti-glare hard coat film is placed on the display screen of a 264 ppi (pixel / inch) display device (New iPad (registered trademark) manufactured by Apple Inc.), and the anti-glare hard coat layer faces upward. I installed it like this.
Next, the display device was driven to display a predetermined image (black) on the entire surface, and the whiteness of the obtained antiglare hard coat film was evaluated according to the following criteria.
◯: No white-brownness was observed, and no decrease in visibility was observed.
Δ: A little white-brownness was observed, and a slight decrease in visibility was observed.
X: White-brownness was observed, and the accompanying decrease in visibility was significantly observed.

(4) Evaluation 4 (anti-glare)
The opposite surface of the antiglare hardcoat layer in the obtained antiglare hardcoat film and the blackboard were attached to the blackboard by using a transparent optical adhesive material (OPTERIA NO-T015, manufactured by Lintec Corporation), which is a double-sided tape. I pasted them together.
Next, a three-wavelength fluorescent lamp was turned on above the antiglare hard coat film, and the antiglare property was evaluated according to the following criteria based on the visible state of the fluorescent lamp visually recognized by the reflection of the antiglare hard coat film. ..
◯: The outline of the fluorescent lamp that is visually recognized is blurred.
Δ: The outline of the visible fluorescent lamp was slightly blurred.
X: The outline of the visible fluorescent lamp was not blurred.

(5) Evaluation 5 (glare)
The anti-glare hard coat film obtained is 10 cm away from the display screen of a 264 ppi (pixel / inch) display device (New iPad (registered trademark) manufactured by Apple Inc.), and the anti-glare hard coat layer is placed above. I installed it so that it faces.
Next, the display device was driven to display the entire display screen in green, and the glare suppression property of the obtained antiglare hard coat film was evaluated according to the following criteria.
◯: No glare was observed.
Δ: A little glare was observed.
X: Glitter was noticeably observed.

(6) Evaluation 6 (image visibility)
The anti-glare hard coat film obtained is 10 cm away from the display screen of a 264 ppi (pixel / inch) display device (New iPad (registered trademark) manufactured by Apple Inc.), and the anti-glare hard coat layer is placed above. I installed it so that it faces.
Next, the display device is driven to display a predetermined image (● ▲ ■) as shown in FIG. 4A, and the image visibility of the obtained antiglare hard coat film is checked according to the following criteria. evaluated.
◯: The outline of the predetermined image can be clearly seen and can be sufficiently recognized.
Δ: Although the outline of the predetermined image is blurred, it can be almost recognized.
X: The outline of the predetermined image is blurred and cannot be sufficiently recognized.

(7) Evaluation 7 (Surface hardness / scratch resistance)
The surface hardness (scratch resistance) of the obtained antiglare hard coat film was evaluated.
First, the obtained antiglare hard coat film was cut out and used as a 10 cm × 10 cm test piece (5 sheets).
The five test pieces were placed on a flat surface with the antiglare hardcoat layer facing upward, and the antiglare hardcoat layer was placed according to the pencil hardness test (JIS K 5600-5-4). The surface hardness of was evaluated.
Further, using # 0000 steel wool, the antiglare hardcoat layer of the obtained antiglare hardcoat film was subjected to a 10 reciprocating rubbing test with a load of ^{250 g / cm 2 at a sliding distance of 10 cm.} ..
Then, the appearance change (the number of scratches) in the antiglare hard coat layer was visually confirmed under a three-wavelength fluorescent lamp, and evaluated according to the following criteria.
◯: The average value of the obtained surface hardness is 2H or more, and the number of scratches is less than three.
Δ: The average value of the obtained surface hardness is less than 2H, 1H or more, and the occurrence of scratches is less than 4 to 10.
X: The average value of the obtained surface hardness is less than 1H, and the number of scratches is 11 or more.

(8) Evaluation 8 (curl property)
The obtained antiglare hard coat film was cut out and used as a 10 cm × 10 cm test piece (5 sheets).
Five test pieces were placed on a flat surface with the antiglare hard coat layer facing upward, and the maximum height of the four corners was measured and obtained according to the following criteria. The curl property of the antiglare hard coat film was evaluated.
The curl property of the obtained antiglare hard coat film was evaluated.
◯: The average value of the maximum height is 10 mm or less.
Δ: The average value of the maximum height is more than 10 mm and 15 mm or less.
X: The average value of the maximum height is more than 15 mm and 16 mm or less.

[Example 2]
In Example 2, an antiglare hard coat film was produced and evaluated in the same manner as in Example 1, except that the amount of the component (B1) in the antiglare hard coat layer forming material was increased to 10 parts by mass. ..

[Example 3]
In Example 3, the amount of the component (B1) compounded in the antiglare hard coat layer forming material was increased to 10 parts by mass, and the amount of the component (B3) compounded was decreased to 10 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in 1.

[Example 4]
In Example 4, the blending amount of the component (B1) in the antiglare hard coat layer forming material was increased to 16 parts by mass, and the blending amount of the component (B3) was reduced to 8 parts by mass, and further, the antiglare property was obtained. An antiglare hard coat film was produced and evaluated in the same manner as in Example 1 except that the film thickness of the hard coat layer was 5 μm.

[Example 5]
In Example 5, an antiglare hard coat film was produced and evaluated in the same manner as in Example 1, except that the blending amount of the component (B3) in the antiglare hard coat layer forming material was slightly reduced to 10 parts by mass. did.

[Comparative Example 1]
In Comparative Example 1, an antiglare hard coat film was produced and evaluated in the same manner as in Example 1 except that the component (B1) in the antiglare hard coat layer forming material was increased to 30 parts by mass.
In the evaluation of image visibility, although the display device was driven to display a predetermined image (● ▲ ■), as shown in FIG. 4 (b), the outline of the predetermined image was blurred and could be sufficiently recognized. could not.

[Comparative Example 2]
In Comparative Example 2, an antiglare hard coat film was produced and evaluated in the same manner as in Example 1 except that the component (B3) in the antiglare hard coat layer forming material was increased to 30 parts by mass.

[Comparative Example 3]
In Comparative Example 3, the component (B1) was increased to 10 parts by mass, the component (B2) was increased to 20 parts by mass, and the component (B3) was also significantly increased to 30 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in 1.

[Comparative Example 4]
In Comparative Example 4, the component (B1) in the antiglare hard coat layer forming material was significantly increased to 30 parts by mass, the component (B2) was increased to 20 parts by mass, and the component (B3) was also increased to 30 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in Example 1, except that the amount was significantly increased.

[Comparative Example 5]
In Comparative Example 5, the amount of the component (B1) in the antiglare hard coat layer forming material was significantly increased to 30 parts by mass, and the component (B3) was reduced to 10 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in the above.

[Comparative Example 6]
In Comparative Example 6, the blending amount of the component (B1) in the antiglare hard coat layer forming material was increased to 20 parts by mass, the component (B2) was reduced to 5 parts by mass, and the component (B3) was 6 parts by mass. An antiglare hardcoat film was produced and evaluated in the same manner as in Example 1, except that the film thickness was reduced to 10 μm and the film thickness of the antiglare hardcoat layer was increased to 10 μm.

[Comparative Example 7]
In Comparative Example 7, the blending amount of the component (B1) in the antiglare hard coat layer forming material was increased to 24 parts by mass, the component (B2) was reduced to 3 parts by mass, and the component (B3) was also 4 parts by mass. An antiglare hardcoat film was produced and evaluated in the same manner as in Example 1, except that the film thickness was reduced to 15 μm and the film thickness of the antiglare hardcoat layer was increased to 15 μm.

[Comparative Example 8]
In Comparative Example 8, the average particle size of the component (B1) in the antiglare hard coat layer forming material was set to 1.5 μm, which was blended at a ratio of 30 parts by mass, and the component (B3) was reduced to 10 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in Example 1.

[Comparative Example 9]
In Comparative Example 9, the antiglare hard was the same as in Example 1 except that the component (B2) in the antiglare hard coat layer forming material was not blended and the component (B3) was reduced to 2 parts by mass. A coated film was manufactured and evaluated.

[Comparative Example 10]
In Comparative Example 10, the blending amount of the component (B1) in the antiglare hard coat layer forming material was increased to 10 parts by mass, the component (B2) was not blended, and the component (B3) was reduced to 2 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in Example 1 except that the amount was significantly reduced.

[Comparative Example 11]
In Comparative Example 11, the blending amount of the component (B1) in the antiglare hard coat layer forming material was increased to 30 parts by mass, the component (B2) was not blended, and the component (B3) was increased to 4 parts by mass. An antiglare hard coat film was produced and evaluated in the same manner as in Example 1 except that the amount was reduced.

[Comparative Example 12]
In Comparative Example 12, the amount of the component (B1) compounded in the antiglare hard coat layer forming material was reduced to 3 parts by mass, and the components (B2) and (B3) were not compounded. An antiglare hard coat film was produced and evaluated in the same manner as in the above.

[Comparative Example 13]
In Comparative Example 13, an antiglare hard coat film was produced and evaluated in the same manner as in Example 1 except that the component (B2) and the component (B3) in the antiglare hard coat layer forming material were not blended.

[Comparative Example 14]
In Comparative Example 14, the amount of the component (B1) compounded in the antiglare hard coat layer forming material was increased to 10 parts by mass, and the components (B2) and (B3) were not compounded. An antiglare hard coat film was produced and evaluated in the same manner as in 1.

[Comparative Example 15]
In Comparative Example 15, the amount of the component (B1) blended in the antiglare hard coat layer forming material was increased to 15 parts by mass, and the components (B2) and (B3) were not blended. An antiglare hard coat film was produced and evaluated in the same manner as in 1.

[Comparative Example 16]
In Comparative Example 16, the amount of the component (B1) blended in the antiglare hard coat layer forming material was significantly increased to 30 parts by mass, and the components (B2) and (B3) were not blended. An antiglare hard coat film was produced and evaluated in the same manner as in Example 1.

As described in detail above, according to the present invention, at least three kinds of particles are blended in a predetermined ratio with the antiglare hardcoat layer forming material for forming the antiglare hardcoat layer, and the thickness is increased. By limiting the amount to a predetermined value or less, it is possible to effectively prevent white-brownness, exhibit excellent antiglare properties, and further, even if the antiglare hard coat layer is relatively thin, it has a high surface hardness. At the same time, it has become possible to obtain an antiglare hard coat film with less curling.
Further, according to the present invention, an antiglare hard coat film capable of effectively suppressing the occurrence of glare while improving image visibility can be obtained even when applied to a high-definition display such as a car navigation system. It came to be.
Moreover, according to the present invention, since the antiglare hard coat film as a whole can be easily thinned, the manufacturing process can be simplified and the manufacturing cost can be reduced.
Therefore, according to the present invention, an antiglare hard coat film capable of effectively suppressing the occurrence of glare while improving image visibility can be obtained even when applied to a high-definition display such as a car navigation system. It came to be.
Moreover, according to the antiglare hard coat film of the present invention, even if the antiglare hard coat layer is formed only on one side without forming on both sides of the plastic base material, the predetermined antiglare property is obtained. It has been found that curl generation can be prevented while exhibiting such factors.
Therefore, the antiglare hard coat film as a whole can be easily thinned, so that the manufacturing process can be simplified and the manufacturing cost can be significantly reduced.

10: Anti-glare hard coat film 12: Plastic base material 14: Predetermined plurality of particles 14a: Silica particles 14b: High refractive index particles (zirconium oxide particles)
14c: Resin particles 15: Active energy ray-curable resin 16: Anti-glare hard coat layer 110: Anti-glare hard coat film 112a: Plastic base material (first TAC film)
112b: Plastic base material (second TAC film)
115a: Adhesive layer (first adhesive layer)
115b: Adhesive layer (second adhesive layer)
116: Anti-glare hard coat layer 118: Adhesive layer 119: Release sheet 120: Polarizing plate

Claims (5)

An antiglare hardcoat film having an antiglare hardcoat layer on the surface of a plastic substrate.
The antiglare hard coat layer
(A) With respect to 100 parts by mass of active energy ray-curable resin as a component
(B1) Silica particles as a component were added to 5 to 25 parts by mass.
The high-refractive index particles having an average particle size in the range of 1 to 500 nm as the component (B2), and the high-refractive index particles as inorganic fine particles having a refractive index of 1.8 or more are 3 to 3. With 30 parts by mass
(B3) Resin particles as a component, 4 to 25 parts by mass,
It is an antiglare hardcoat layer having a thickness of 8 μm or less, which is derived from a material for forming an antiglare hardcoat layer containing.
The average particle size of the silica particles was set to a value within the range of 2.1 to 10 μm.
The average particle size of the resin particles is set to a value within the range of 0.5 to 2 μm, and
An antiglare hard coat film, characterized in that the silica particles project from the surface of the antiglare hardcoat layer on the side opposite to the plastic base material. The antiglare hard coat film according to claim 1, wherein the silica particles are crushed silica particles. The overall haze value of the antiglare hard coat film measured in accordance with JIS K 7136 shall be in the range of 15 to 40%, the internal haze value shall be in the range of 5 to 38%, and the external haze value shall be in the range of 5 to 38%. The antiglare hard coat film according to claim 1 or 2 , wherein the haze value is less than 40%. The antiglare hardcoat film according to any one of claims 1 to 3, wherein the surface hardness of the antiglare hardcoat layer is 2H or more. A method for producing an antiglare hardcoat film having an antiglare hardcoat layer on the surface of a plastic base material.
A method for producing an antiglare hard coat film, which comprises at least steps (1) to (3).
(1) 5 to 5 silica particles having an average particle size in the range of 2.1 to 10 μm as the component (B1) with respect to 100 parts by mass of the active energy ray-curable resin as the component (A). The high refraction of 25 parts by mass and the component (B2) as an inorganic fine particle having an average particle size in the range of 1 to 500 nm and having a refractive index of 1.8 or more. Antiglare by blending 3 to 30 parts by mass of rate particles and 4 to 25 parts by mass of resin particles having an average particle size in the range of 0.5 to 2 μm as the component (B3). Step of forming a hard coat layer forming material (2) A step of applying the antiglare hard coat layer forming material on a base material to form a coating film (3) With respect to the coating film on the base material Then, the active energy rays are irradiated to form an antiglare hardcoat layer having a thickness of 8 μm or less, in which the silica particles protrude from the surface of the antiglare hardcoat layer opposite to the plastic substrate. Process to do.

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