JP7343273B2 - Anti-glare film, method for producing anti-glare film, optical member and image display device - Google Patents

Description

The present invention relates to an anti-glare film, a method for producing an anti-glare film, an optical member, and an image display device.

Various image display devices, such as a cathode tube display (CRT), a liquid crystal display (LCD), a plasma display panel (PDP), and an electroluminescent display (ELD), are equipped with fluorescent lamps or sunlight on the surface of the image display device. Anti-glare films are used to prevent contrast reduction due to the reflection of external light and image reflections.In particular, as the screens of image display devices become larger, anti-glare films are being used. The number of image display devices worn is increasing.

There are many documents describing anti-glare films, for example, Patent Documents 1 and 2.

Japanese Patent Application Publication No. 2009-109683 Japanese Patent Application Publication No. 2003-202416

In anti-glare films, a wavy black and white color difference (hereinafter referred to as "white haze") may occur when a light source is reflected. In a display (image display device) or the like using an anti-glare film, if the occurrence of white haze is significant, the quality of the appearance may deteriorate.

Therefore, an object of the present invention is to provide an anti-glare film, a method for producing an anti-glare film, an optical member, and an image display device in which the occurrence of white mist is suppressed.

In order to achieve the above object, the first anti-glare film of the present invention includes:
An anti-glare film in which an anti-glare layer (B) is laminated on a light-transparent substrate (A),
Irregularities are formed on the outermost surface of the anti-glare layer (B) side of the anti-glare film,
The unevenness is characterized in that it satisfies the following formulas (1) and (2).

θa≦0.24 (1)
Rz≦0.20 (2)

In the formula (1), θa is the average inclination angle [°] of the unevenness,
In the formula (2), Rz is the ten-point average height [μm] of the unevenness.

In order to achieve the above object, the second anti-glare film of the present invention includes:
An anti-glare film in which an anti-glare layer (B) and other layers are laminated in the above order on a light-transmitting substrate (A),
unevenness is formed on the outermost surface of the other layer,
The unevenness is characterized in that it satisfies the following formulas (1) and (2). In addition, below, the 1st and 2nd anti-glare film of this invention may be collectively called "the anti-glare film of this invention."

θa≦0.24 (1)
Rz≦0.20 (2)

In the formula (1), θa is the average inclination angle [°] of the unevenness,
In the formula (2), Rz is the ten-point average height [μm] of the unevenness.

The method for producing an anti-glare film of the present invention includes:
an anti-glare layer (B) forming step of forming the anti-glare layer (B) on the light-transmissive substrate (A);
an unevenness forming step of forming the unevenness on the outermost surface of the antiglare layer (B) side of the antiglare film so as to satisfy the formulas (1) and (2);
The anti-glare layer (B) forming step includes a coating step of coating a coating solution on the light-transmitting substrate (A), and drying the applied coating solution to form a coating film. A coating film forming step,
The coating liquid is characterized in that it contains a resin and a solvent.

The optical member of the present invention is an optical member containing the antiglare film of the present invention.

The image display device of the present invention is an image display device including the antiglare film of the present invention or the optical member of the present invention.

According to the present invention, it is possible to provide an anti-glare film in which generation of white haze is suppressed, a method for manufacturing an anti-glare film, an optical member, and an image display device.

FIG. 1 is a sectional view showing an example of the structure of the anti-glare film of the present invention. FIG. 2 is a cross-sectional view showing another example of the structure of the anti-glare film of the present invention. FIG. 3 is a sectional view showing still another example of the structure of the anti-glare film of the present invention. FIG. 4 is a sectional view showing still another example of the structure of the anti-glare film of the present invention.

Next, the present invention will be explained in more detail by giving examples. However, the present invention is not limited in any way by the following explanation.

The anti-glare film of the present invention may further satisfy the following formula (3), for example.

Ra≦0.050 (3)

In the formula (3), Ra is the arithmetic mean surface roughness [μm] of the unevenness.

In the anti-glare film of the present invention, for example, another layer may be further laminated on the surface of the anti-glare layer (B) opposite to the light-transmitting substrate (A). The other layer may be, for example, a low reflection layer.

In the antiglare film of the present invention, for example, the antiglare layer (B) may contain a binder resin and a cohesive filler. The cohesive filler may be, for example, an organoclay.

In the antiglare film of the present invention, for example, the antiglare layer (B) may not contain particles.

In the method for producing an anti-glare film of the present invention, for example, the anti-glare layer (B) forming step may further include a curing step of curing the coating film.

In the method for producing an anti-glare film of the present invention, for example, the solvent may contain toluene and methyl ethyl ketone.

In the method for producing an anti-glare film of the present invention, for example, the anti-glare film is an anti-glare film containing the other layer, and the unevenness forming step is performed on the anti-glare layer (B). It may also include other layer forming steps for forming other layers.

The optical member of the present invention may be, for example, a polarizing plate.

[1. Anti-glare film]
As described above, the first anti-glare film of the present invention is an anti-glare film in which an anti-glare layer (B) is laminated on a light-transmitting substrate (A), It is characterized in that irregularities are formed on the outermost surface on the anti-glare layer (B) side, and the irregularities satisfy the following formulas (1) and (2).

θa≦0.24 (1)
Rz≦0.20 (2)

In the formula (1), θa is the average inclination angle [°] of the unevenness,
In the formula (2), Rz is the ten-point average height [μm] of the unevenness.

As described above, the second anti-glare film of the present invention is an anti-glare film in which the anti-glare layer (B) and other layers are laminated in the above order on the light-transmitting substrate (A). , unevenness is formed on the outermost surface of the other layer, and the unevenness satisfies the following formulas (1) and (2).

θa≦0.24 (1)
Rz≦0.20 (2)

In the formula (1), θa is the average inclination angle [°] of the unevenness,
In the formula (2), Rz is the ten-point average height [μm] of the unevenness.

The cross-sectional view of FIG. 1 shows an example of the structure of the anti-glare film of the present invention. As shown in the figure, in this anti-glare film 10, an anti-glare layer (B) 12 is laminated on one surface of a light-transmissive base material (A) 11. The antiglare layer (B) 12 includes particles 12b and a thixotropy agent 12c in a resin layer 12a. A low reflection layer (C) 13 is further laminated as the other layer on the surface of the anti-glare layer (B) 12 opposite to the light-transmitting base material (A) 11. Irregularities are formed on the outermost surface of the anti-glare layer (B) 12 side of the anti-glare film 10 (the surface of the low-reflection layer (C) 13 on the opposite side to the light-transmitting base material (A) 11). There is. The average inclination angle θa of the unevenness is 0.24° or less as described above, and the ten-point average height (also referred to as ten-point average roughness or ten-point average surface roughness) Rz of the unevenness is as described above. It is 0.20 μm or less. However, the antiglare film of the present invention is not limited thereto; for example, the particles 12b, the thixotropy imparting agent 12c, and the other layer (low reflection layer (C)) 13 may be present or absent, respectively.

The cross-sectional view of FIG. 2 shows another example of the structure of the anti-glare film of the present invention. As shown, the structure of this anti-glare film 10 is the same as that of the anti-glare film 10 in FIG. 1 except that there is no other layer (low reflection layer (C)) 13. In the anti-glare film 10 shown in FIG. , unevenness is formed. The average inclination angle θa of the unevenness is 0.24° or less, and the ten-point average height Rz of the unevenness is 0.20 μm or less.

The cross-sectional view of FIG. 3 shows yet another example of the structure of the anti-glare film of the present invention. As shown, the structure of this anti-glare film 10 is the same as that in FIG. 1 except that the anti-glare layer (B) 12 does not contain particles 12b. Furthermore, the cross-sectional view of FIG. 4 shows yet another example of the structure of the anti-glare film of the present invention. As illustrated, the structure of this anti-glare film 10 is the same as that in FIG. 2 except that the anti-glare layer (B) 12 does not contain particles 12b.

In addition, in the anti-glare film of the present invention, "the outermost surface on the anti-glare layer (B) side" is the outermost surface on the anti-glare layer (B) side. Specifically, "the outermost surface on the anti-glare layer (B) side" refers to the light-transmitting base material in the anti-glare layer (B) when the other layer is not present (for example, FIGS. 2 and 4). This is the surface opposite to (A). In addition, "the outermost surface on the anti-glare layer (B) side" refers to the other layer (low reflection layer (C) 13 in FIGS. 1 and 3) when the other layer is present (for example, in FIGS. 1 and 3). ) is the outermost surface on the opposite side to the translucent base material (A).

The anti-glare film of the present invention has excellent anti-glare properties even when the above-mentioned θa and Rz are small and the irregularities on the outermost surface are smooth, and as described above, the occurrence of white mist can be suppressed. In particular, in a general anti-glare film, when a low reflection layer is provided on the anti-glare layer, the occurrence of white haze may become more noticeable. However, according to the anti-glare film of the present invention, even when the low-reflection layer (C) is provided on the anti-glare layer (B), for example, the occurrence of white mist can be suppressed.

Further, in FIGS. 1 and 3, the other layer is the low reflection layer (C) 13, but in the antiglare film of the present invention, the other layer is not limited to only the low reflection layer. The other layers may be, for example, a low refractive index layer, a low reflection layer, a conductive layer, an antifouling layer, a high hardness layer, a high refractive index layer, a UV absorption layer, etc. The other layer may be a single layer or a plurality of layers, and in the case of a plurality of layers, it may be of one type or a plurality of types. For example, the other layer may be an optical thin film whose thickness and refractive index are strictly controlled, or a stack of two or more optical thin films.

As described above, the anti-glare film of the present invention has an average inclination angle θa (°) of 0.24 or less in the uneven shape of the outermost surface on the anti-glare layer (B) side. The average inclination angle θa may be, for example, 0.23° or less, 0.20° or less, or 0.19° or less. The lower limit of the average inclination angle θa is not particularly limited, but is, for example, a value of 0° or more or more than 0°, 0.10° or more, 0.11° or more, 0.13° or more, or 0.15 It may be more than °. The average inclination angle θa is, for example, more than 0° and less than 0.23°, more than 0.10° and less than 0.23°, more than 0.11° and less than 0.23°, and more than 0.13° and less than 0.23°. 0.15° or more and 0.23° or less, 0° or more and 0.20° or less, 0.10° or more and 0.20° or less, 0.11° or more and 0.20° or less, and 0.13° or more 0.20° or less, 0.15° or more and 0.20° or less, over 0° and 0.19° or less, 0.10° or more and 0.19° or less, 0.11° or more and 0.19° or less, 0 The angle may be greater than or equal to .13° and less than or equal to 0.19°, or greater than or equal to 0.15° and less than or equal to 0.19°. Here, the average inclination angle θa is a value defined by the following formula (3). The average inclination angle θa can be measured, for example, by the method described in Examples below.

Average inclination angle θa=tan ^-1 Δa (3)

In the above formula (3), Δa is the distance between the peaks and valleys of adjacent peaks in the standard length L of the roughness curve specified in JIS B 0601 (1994 edition), as shown in the formula (4) below. This is the value obtained by dividing the total (h1+h2+h3...+hn) of the difference (height h) from the lowest point by the reference length L. The roughness curve is a curve obtained by removing surface waviness components longer than a predetermined wavelength from a cross-sectional curve using a phase difference compensating high-pass filter. Further, the cross-sectional curve is a contour that appears at a cut end when the target surface is cut by a plane perpendicular to the target surface.

Δa=(h1+h2+h3...+hn)/L (4)

Further, in the antiglare film of the present invention, as described above, in the uneven shape of the outermost surface on the antiglare layer (B) side, the ten point average height Rz of the unevenness is 0.20 μm or less. The ten-point average height Rz may be, for example, 0.19 μm or less, or 0.18 μm or less. The lower limit of the ten-point average height Rz is not particularly limited, but is, for example, a value of 0 μm or more or more than 0 μm, 0.10 μm or more, 0.12 μm or more, 0.13 μm or more, or 0.17 μm or more. It's okay. The ten-point average height Rz is, for example, more than 0 μm and less than 0.20 μm, more than 0.10 μm and less than 0.20 μm, more than 0.12 μm and less than 0.20 μm, more than 0.13 μm and less than 0.20 μm, and more than 0.17 μm 0.20μm or less, over 0μm and 0.19μm or less, 0.10μm or more and 0.19μm or less, 0.12μm or more and 0.19μm or less, 0.13μm or more and 0.19μm or less, 0.17μm or more and 0.19μm or less, 0μm 0.18 μm or more and 0.18 μm or less, 0.12 μm or more and 0.18 μm or less, 0.13 μm or more and 0.18 μm or less, or 0.17 μm or more and 0.18 μm or less. The ten-point average height Rz can be measured, for example, by the method described in Examples below.

In the uneven shape of the outermost surface on the anti-glare layer (B) side, the arithmetic mean surface roughness (also referred to as arithmetic mean height) Ra is not particularly limited, but for example, as described above, it is 0.050 μm or less. Good too. The arithmetic mean surface roughness Ra may be, for example, 0.048 μm or less, 0.045 μm or less, or 0.043 μm or less. The lower limit value of the arithmetic mean surface roughness Ra is not particularly limited, but is, for example, a value of 0 μm or more or more than 0 μm, 0.010 μm or more, 0.020 μm or more, 0.030 μm or more, or 0.035 μm or more. It's okay. The arithmetic mean surface roughness Ra is, for example, more than 0 μm and less than 0.050 μm, more than 0.010 μm and less than 0.050 μm, more than 0.020 μm and less than 0.050 μm, more than 0.030 μm and less than 0.050 μm, and more than 0.035 μm 0.050μm or less, over 0μm and 0.048μm or less, 0.010μm or more and 0.048μm or less, 0.020μm or more and 0.048μm or less, 0.030μm or more and 0.048μm or less, 0.035μm or more and 0.048μm or less, 0μm more than 0.045 μm, 0.010 μm to 0.045 μm, 0.020 μm to 0.045 μm, 0.030 μm to 0.045 μm, 0.035 μm to 0.045 μm, more than 0 μm to 0.043 μm , 0.010 μm or more and 0.043 μm or less, 0.020 μm or more and 0.043 μm or less, 0.030 μm or more and 0.043 μm or less, or 0.035 μm or more and 0.043 μm or less. In order to prevent external light and images from being reflected on the surface of the anti-glare hard coat film, it is preferable that the surface be rough to some extent, that is, Ra should be large to some extent. When the Ra is within the above range, for example, when used in an image display device, scattering of reflected light when viewed from an oblique direction is suppressed, white blur is improved, and contrast in bright places is also improved. can be improved. In the present invention, the "arithmetic mean surface roughness Ra" is the arithmetic mean surface roughness Ra defined in JIS B 0601 (1994 edition).

Regarding the uneven shape of the outermost surface on the anti-glare layer (B) side, the average distance between the unevenness Sm (mm) on the surface is not particularly limited, but may be in the range of 0.025 to 0.275, for example. This results in, for example, an anti-glare hard coat film that has excellent anti-glare properties and can prevent white blurring. In the present invention, the average distance between concavities and convexities Sm (mm) on the surface of the anti-glare layer (B) is defined as the average distance between concavities and convexities Sm (mm) on the surface measured according to JIS B0601 (1994 edition). The Sm may be, for example, 0.050 mm or more, 0.075 mm or more, 0.100 mm or more, or 0.125 mm or more, and 0.250 mm or less, 0.225 mm or less, 0.200 mm or less, or 0. It may be 175 mm or less. The Sm is, for example, 0.050 mm or more and 0.250 mm or less, 0.050 mm or more and 0.225 mm or less, 0.050 mm or more and 0.200 mm or less, 0.050 mm or more and 0.175 mm or less, and 0.075 mm or more and 0.250 mm or less. , 0.075 mm or more and 0.225 mm or less, 0.075 mm or more and 0.200 mm or less, 0.075 mm or more and 0.175 mm or less, 0.100 mm or more and 0.250 mm or less, 0.100 mm or more and 0.225 mm or less, 0.100 mm or more 0.200mm or less, 0.100mm or more and 0.175mm or less, 0.125mm or more and 0.250mm or less, 0.125mm or more and 0.225mm or less, 0.125mm or more and 0.200mm or less, or 0.125mm or more and 0.175mm or less It may be.

In the anti-glare film of the present invention, the haze value is not particularly limited, but may be within the range of 0 to 10%, for example. The haze value is the haze value (cloudiness) of the entire anti-glare film according to JIS K 7136 (2000 edition). The haze value is more preferably in the range of 0 to 5%, and even more preferably in the range of 0 to 3%. In order to keep the haze value within the above range, it is preferable to select the particles and the resin so that the difference in refractive index between the particles and the resin is in the range of 0.001 to 0.02. When the haze value is within the above range, a clear image can be obtained and the contrast in a dark place can be improved.

Hereinafter, each of the light-transmitting substrate (A), the anti-glare layer (B), and the other layer will be further explained by giving examples. In the following, the case where the anti-glare layer (B) is an anti-glare hard coat layer and the case where the other layer is a low-reflection layer (C) will be mainly explained, but the present invention is not limited to this.

The light-transmitting substrate (A) is not particularly limited, and examples thereof include transparent plastic film substrates and the like. The transparent plastic film substrate is not particularly limited, but preferably has excellent visible light transmittance (preferably 90% or more light transmittance) and excellent transparency (preferably haze value 1% or less). , for example, the transparent plastic film base material described in JP-A-2008-90263. As the transparent plastic film base material, one having optically low birefringence is suitably used. The anti-glare film of the present invention can also be used, for example, as a protective film in a polarizing plate. In this case, the transparent plastic film base material may include triacetyl cellulose (TAC), polycarbonate, acrylic polymer, A film formed from polyolefin or the like having a cyclic or norbornene structure is preferred. Furthermore, in the present invention, as described later, the transparent plastic film base material may be a polarizer itself. With such a configuration, a protective layer made of TAC or the like is not required and the structure of the polarizing plate can be simplified, thereby reducing the number of manufacturing steps of the polarizing plate or the image display device and improving production efficiency. Moreover, with such a configuration, the polarizing plate can be made thinner. In addition, when the said transparent plastic film base material is a polarizer, the said anti-glare layer (B) and the said low reflection layer (C) will play a role as a protective layer. Further, with such a configuration, the anti-glare film also functions as a cover plate when it is attached to the surface of the liquid crystal cell, for example.

In the present invention, the thickness of the light-transmitting substrate (A) is not particularly limited, but in consideration of workability such as strength and handleability, and thin layer property, the thickness is, for example, 10 to 500 μm, 20 to 300 μm. , or in the range of 30 to 200 μm. The refractive index of the light-transmitting substrate (A) is not particularly limited. The refractive index is, for example, in the range of 1.30 to 1.80 or 1.40 to 1.70.

In the antiglare film of the present invention, for example, the resin contained in the light-transmitting substrate (A) may include an acrylic resin.

In the anti-glare film of the present invention, for example, the light-transmitting substrate (A) may be an acrylic film.

In the antiglare film of the present invention, for example, the antiglare layer (B) may contain a resin and a filler. The filler may include at least one of particles and a thixotropic agent.

For example, the anti-glare layer (B) does not contain particles and contains a thixotropy imparting agent, so that the anti-glare film of the present invention can have small θa and Rz and smooth irregularities on the outermost surface. can. Furthermore, the antiglare layer (B) of the present invention, in which the θa and Rz are small and the unevenness of the outermost surface is smooth, can also be obtained by including a thixotropy imparting agent and particles having a small particle size. It can be made into a sexual film.

In the anti-glare film of the present invention, for example, the resin contained in the anti-glare layer (B) may include an acrylate resin (also referred to as acrylic resin).

In the anti-glare film of the present invention, for example, the resin contained in the anti-glare layer (B) may contain a urethane acrylate resin.

In the anti-glare film of the present invention, for example, the resin contained in the anti-glare layer (B) may be a copolymer of a curable urethane acrylate resin and a polyfunctional acrylate.

In the antiglare film of the present invention, for example, the antiglare layer (B) is formed using an antiglare layer forming material containing a resin and a filler, and the antiglare layer (B) is formed using an antiglare layer forming material containing a resin and a filler. The antiglare layer (B) may have an agglomerated portion that forms a convex portion on the surface of the antiglare layer (B) by aggregating. Further, in the agglomerated portion forming the convex portion, a plurality of the fillers may be present in a state where they are gathered in one direction in the surface direction of the anti-glare layer (B). In the image display device of the present invention, the anti-glare film of the present invention may be arranged such that, for example, one direction in which the plurality of fillers are gathered coincides with the long side direction of the black matrix pattern.

In the antiglare film of the present invention, the thixotropy imparting agent may be, for example, at least one selected from the group consisting of organic clay, oxidized polyolefin, and modified urea. Moreover, the thixotropy imparting agent may be, for example, a thickener.

In the anti-glare film of the present invention, for example, the thixotropy imparting agent may be contained in a range of 0.2 to 5 parts by weight based on 100 parts by weight (mass) of the resin of the anti-glare layer (B). good.

In the anti-glare film of the present invention, the particles are contained in an amount of, for example, 0.2 to 12 parts by weight or 0.5 to 12 parts by weight based on 100 parts by weight of the resin of the anti-glare layer (B). It may be

In the method for producing an anti-glare film of the present invention, the surface shape of the anti-glare film is further adjusted by adjusting the number of parts by weight of the particles based on 100 parts by weight of the resin in the anti-glare layer forming material. It's okay.

By having an agglomerated portion in which particles are aggregated, for example, the anti-glare film of the present invention can have a gentle uneven shape. Further, for example, by having the agglomerated portion, the average distance Sm (mm) between the unevenness on the surface of the antiglare layer (B) increases. An anti-glare film having such a surface shape can effectively prevent reflections of fluorescent lights and the like. However, the anti-glare film of the present invention is not limited to this.

The anti-glare layer (B) can be formed, for example, by applying a coating liquid containing the resin, the filler and a solvent to at least one surface of the light-transmitting substrate (A), as described below. It is formed by forming a film and then removing the solvent from the coating. Examples of the resin include thermosetting resins and ionizing radiation-curable resins that are cured by ultraviolet light or light. As the resin, it is also possible to use commercially available thermosetting resins, ultraviolet curable resins, and the like.

As the thermosetting resin or the ultraviolet curable resin, for example, a curable compound having at least one of an acrylate group and a methacrylate group that is cured by heat, light (such as ultraviolet rays), or electron beam, etc. can be used, for example, Silicone resins, polyester resins, polyether resins, epoxy resins, urethane resins, alkyd resins, spiroacetal resins, polybutadiene resins, polythiol polyene resins, oligomers or prepolymers such as acrylates and methacrylates of polyfunctional compounds such as polyhydric alcohols, etc. can give. These may be used alone or in combination of two or more.

For example, a reactive diluent having at least one of an acrylate group and a methacrylate group can also be used in the resin. The reactive diluent can be, for example, the reactive diluent described in JP-A No. 2008-88309, and includes, for example, monofunctional acrylate, monofunctional methacrylate, polyfunctional acrylate, polyfunctional methacrylate, and the like. As the reactive diluent, trifunctional or higher functional acrylates or trifunctional or higher functional methacrylates are preferred. This is because the hardness of the anti-glare layer (B) can be made excellent. Examples of the reactive diluent include butanediol glycerol ether diacrylate, isocyanuric acid acrylate, isocyanuric acid methacrylate, and the like. These may be used alone or in combination of two or more.

The particles for forming the anti-glare layer (B) impart anti-glare properties by making the surface of the anti-glare layer (B) uneven, and also increase the haze value of the anti-glare layer (B). Its main function is to control. The haze value of the anti-glare layer (B) can be designed by controlling the difference in refractive index between the particles and the resin. Examples of the particles include inorganic particles and organic particles. The inorganic particles are not particularly limited, and include, for example, silicon oxide particles, titanium oxide particles, aluminum oxide particles, zinc oxide particles, tin oxide particles, calcium carbonate particles, barium sulfate particles, talc particles, kaolin particles, calcium sulfate particles, etc. can be given. The organic particles are not particularly limited, and include, for example, polymethyl methacrylate resin powder (PMMA particles), silicone resin powder, polystyrene resin powder, polycarbonate resin powder, acrylic styrene resin powder, benzoguanamine resin powder, melamine resin powder, polyolefin. Examples include resin powder, polyester resin powder, polyamide resin powder, polyimide resin powder, polyfluoroethylene resin powder, and the like. One type of these inorganic particles and organic particles may be used alone, or two or more types may be used in combination.

The particle diameter (D) (weight average particle diameter) of the particles is not particularly limited, but is, for example, within the range of 2 to 10 μm. By setting the weight average particle diameter of the particles within the above range, it is possible to obtain, for example, an antiglare film that has better antiglare properties and suppresses reflections. From the viewpoint of suppressing reflection from an oblique direction, it is preferable that the weight average particle diameter of the particles is not too small. From the viewpoint of suppressing reflection from the front direction, it is preferable that the weight average particle diameter of the particles is not too large. The weight average particle diameter of the particles may be, for example, 2.2 μm or more, 2.3 μm or more, 2.5 μm or more, or 3.0 μm or more, and 9.0 μm or less, 8.0 μm or less, or 7.0 μm. or less, or 6.0 μm or less. The weight average particle diameter of the particles is, for example, 2.2 μm or more and 9.0 μm or less, 2.2 μm or more and 8.0 μm or less, 2.2 μm or more and 7.0 μm or less, 2.2 μm or more and 6.0 μm or less, and 2.3 μm. 9.0 μm or more, 2.3 μm or more and 8.0 μm or less, 2.3 μm or more and 7.0 μm or less, 2.3 μm or more and 6.0 μm or less, 2.5 μm or more and 9.0 μm or less, 2.5 μm or more and 8.0 μm or less , 2.5 μm or more and 7.0 μm or less, 2.5 μm or more and 6.0 μm or less, 3.0 μm or more and 9.0 μm or less, 3.0 μm or more and 8.0 μm or less, 3.0 μm or more and 7.0 μm or less, or 3.0 μm The thickness may be greater than or equal to 6.0 μm. Note that the weight average particle diameter of the particles can be measured, for example, by the Coulter counting method. For example, using a particle size distribution measuring device (trade name: Coulter Multisizer, manufactured by Beckman Coulter) that uses the pore electrical resistance method, an electrolyte solution corresponding to the volume of the particles when the particles pass through the pores is measured. By measuring electrical resistance, the number and volume of the particles are measured, and the weight average particle diameter is calculated.

The shape of the particles is not particularly limited, and may be, for example, approximately spherical in the form of beads, or irregularly shaped such as powder, but is preferably approximately spherical, and more preferably has an aspect ratio. The particles are approximately spherical particles with a ratio of 1.5 or less, and most preferably spherical particles.

The proportion of the particles in the anti-glare layer (B) is, for example, 0.1 parts by weight or more, 0.2 parts by weight or more, 0.3 parts by weight or more, or 0.5 parts by weight, based on 100 parts by weight of the resin. The amount may be 10 parts by weight or less, 8 parts by weight or less, 7 parts by weight or less, or 6 parts by weight or less. The proportion of the particles is, for example, 0.1 parts by weight or more and 10 parts by weight or less, 0.1 parts by weight or more and 8 parts by weight or less, 0.1 parts by weight or more and 7 parts by weight or less, 0. .1 parts by weight or more and 6 parts by weight or less, 0.2 parts by weight or more and 10 parts by weight or less, 0.2 parts by weight or more and 8 parts by weight or less, 0.2 parts by weight or more and 7 parts by weight or less, 0.2 parts by weight or more6 Parts by weight or less, 0.3 parts by weight or more and 10 parts by weight or less, 0.3 parts by weight or more and 8 parts by weight or less, 0.3 parts by weight or more and 7 parts by weight or less, 0.3 parts by weight or more and 6 parts by weight or less, 0. The amount may be from 5 parts by weight to 10 parts by weight, from 0.5 parts by weight to 8 parts by weight, from 0.5 parts by weight to 7 parts by weight, or from 0.5 parts by weight to 6 parts by weight. By setting the proportion of the particles within the above range, for example, the agglomerated portion can be suitably formed, and, for example, an antiglare film with better antiglare properties and suppressed reflection can be obtained. can.

In the antiglare layer (B), the filler may be particles and a thixotropy imparting agent. The thixotropy-imparting agent may be contained alone, or the particles may further contain the thixotropy-imparting agent in addition to the particles. By including the thixotropy agent, the aggregation state of the particles can be easily controlled. Examples of the thixotropy-imparting agent include organic clay, oxidized polyolefin, and modified urea.

It is preferable that the organic clay is a layered clay that has been subjected to an organic treatment in order to improve its affinity with the resin. The organic clay may be prepared in-house or a commercially available product may be used. Examples of the commercially available products include Lucentite SAN, Lucentite STN, Lucentite SEN, Lucentite SPN, Somasif ME-100, Somasif MAE, Somasif MTE, Somasif MEE, Somasif MPE (trade names, all manufactured by Co-op Chemical Co., Ltd.) ); Esben, Esben C, Esben E, Esben W, Esben P, Esben WX, Esben N-400, Esben NX, Esben NX80, Esben NO12S, Esben NEZ, Esben NO12, Esben NE, Esben NZ, Esben NZ70, Olga Knight, Organite D, Organite T (trade names, all manufactured by Hojun Co., Ltd.); Kunipia F, Kunipia G, Kunipia G4 (trade names, all manufactured by Kunimine Industries Co., Ltd.); Thixogel VZ, Clayton HT, Clayton 40 (Product names, all manufactured by Rockwood Additives).

The oxidized polyolefin may be prepared in-house or a commercially available product may be used. Examples of the commercially available products include Disparon 4200-20 (trade name, manufactured by Kusumoto Kasei Co., Ltd.), Fluonon SA300 (trade name, manufactured by Kyoeisha Chemical Co., Ltd.), and the like.

The modified urea is a reaction product of an isocyanate monomer or its adduct and an organic amine. The modified urea may be prepared in-house or a commercially available product may be used. Examples of the commercially available products include BYK410 (manufactured by Big Chemie).

The thixotropy imparting agent may be used alone or in combination of two or more.

The proportion of the thixotropy imparting agent in the anti-glare layer (B) is preferably in the range of 0.2 to 5 parts by weight, more preferably in the range of 0.4 to 4 parts by weight, based on 100 parts by weight of the resin. be.

The maximum thickness (d') of the anti-glare layer (B) is not particularly limited, but is preferably within the range of 3 to 12 μm. By setting the maximum thickness (d') of the anti-glare layer (B) within the above range, it is possible to prevent, for example, curling in the anti-glare film, thereby reducing productivity problems such as poor conveyance. can be avoided. Further, when the thickness (d) is within the above range, the weight average particle diameter (D) of the particles is preferably within the range of 2 to 10 μm, as described above. Since the maximum thickness (d') of the anti-glare layer (B) and the weight average particle diameter (D) of the particles are in the above-mentioned combination, an anti-glare film with excellent anti-glare properties can be obtained. can. The maximum thickness (d') of the anti-glare layer (B) is more preferably within the range of 3 to 8 μm.

The ratio D/d between the thickness (d') of the anti-glare layer (B) and the weight average particle diameter (D) of the particles is, for example, 1 or less, 0.9 or less, 0.8 or less, 0.7. or less, or 0.6 or less, 0.1 or more, 0.2 or more, 0.3 or more, or 0.4 or more. The D/d is, for example, 0.1 or more and 1 or less, 0.2 or more and 1 or less, 0.3 or more and 1 or less, 0.4 or more and 1 or less, 0.1 or more and 0.9 or less, and 0.2 or more and 0. .9 or less, 0.3 or more and 0.9 or less, 0.4 or more and 0.9 or less, 0.1 or more and 0.8 or less, 0.2 or more and 0.8 or less, 0.3 or more and 0.8 or less, 0 .4 to 0.8, 0.1 to 0.7, 0.2 to 0.7, 0.3 to 0.7, 0.4 to 0.7, 0.1 to 0. It may be 6 or less, 0.2 or more and 0.6 or less, 0.3 or more and 0.6 or less, or 0.4 or more and 0.6 or less. By having such a relationship, it is possible to obtain an anti-glare film that has better anti-glare properties and suppresses reflections.

In the anti-glare film of the present invention, for example, the anti-glare layer (B) has an agglomerated part that forms a convex part on the surface of the anti-glare layer (B) by aggregating the filler. In addition, in the agglomerated portion forming the convex portion, a plurality of the fillers may be present in a state in which they are gathered in one direction in the surface direction of the anti-glare layer (B). This makes it possible to prevent, for example, reflections of fluorescent lights. However, the anti-glare film of the present invention is not limited to this.

Further, the anti-glare film of the present invention may include, for example, a resin derived from the light-transmissive base material (A) and a resin derived from the light-transparent base material (A) between the light-transparent base material (A) and the anti-glare layer (B). It may have an intermediate layer containing a resin derived from the anti-glare layer (B). By controlling the thickness of this intermediate layer, the surface shape of the antiglare layer (B) can be controlled. For example, when the thickness of the intermediate layer is increased, the Rz and θa tend to increase, and when the thickness of the intermediate layer is decreased, the Rz and θa tend to decrease.

In the present invention, the mechanism by which the intermediate layer (also referred to as a permeable layer or a compatible layer) is formed is not particularly limited, but for example, it is formed in the drying step in the method for producing an anti-glare film of the present inventor. . Specifically, for example, in the drying step, the coating liquid for forming the anti-glare layer (B) permeates the light-transmitting base material (A), and the The intermediate layer containing a resin and a resin derived from the anti-glare layer (B) is formed. The resin contained in the intermediate layer is not particularly limited, and for example, the resin contained in the light-transmitting base material (A) and the resin contained in the anti-glare layer (B) are simply mixed (compatible). It may also be something you have. Further, the resin contained in the intermediate layer may be heated, irradiated with light, etc. at least one of the resin contained in the light-transmitting base material (A) and the resin contained in the anti-glare layer (B). It may be chemically changed by

The thickness ratio R of the intermediate layer defined by the following formula (5) is not particularly limited, but is, for example, 0.10 to 0.80, for example, 0.15 or more, 0.20 or more, 0.25 or more, 0.30 or more, 0.40 or more, or 0.45 or more, for example, 0.75 or less, 0.70 or less, 0.65 or less, 0.60 or less, 0.50 or less, It may be 0.40 or less, 0.45 or less, or 0.30 or less. The intermediate layer can be confirmed and its thickness can be measured, for example, by observing a cross section of the anti-glare hard coat film using a transmission electron microscope (TEM).

R=[ _DC /( _DC + _DB )] (5)

In the formula (5), D _B is the thickness [μm] of the antiglare layer (B), and D _C is the thickness [μm] of the intermediate layer.

In the anti-glare film of the present invention, for example, as described above, the anti-glare layer (B) is formed by aggregation in which the filler aggregates to form convex portions on the surface of the anti-glare layer (B). In the agglomerated portion forming the convex portion, a plurality of the fillers may be present in a state of being gathered in one direction in the surface direction of the anti-glare layer (B). As a result, the convex portion has a gentle shape with anisotropy. Since the anti-glare film has the convex portion having such a shape, it is possible to prevent reflections of fluorescent lamps and the like. However, the anti-glare film of the present invention is not limited to this.

The surface shape of the anti-glare layer (B) can be arbitrarily designed by controlling the agglomeration state of the filler contained in the anti-glare layer forming material. The aggregation state of the filler can be controlled by, for example, the material of the filler (for example, the chemical modification state of the particle surface, the affinity for solvents and resins, etc.), the type and combination of resin (binder) or solvent, and the like. Furthermore, the thixotropy-imparting agent allows precise control of the agglomeration state of the particles. As a result, in the present invention, the surface shape of the anti-glare film can be controlled (adjusted) over a wide range, for example, the aggregation state of the filler can be made as described above, and the convex The shaped portion can have a gentle shape. Furthermore, as described above, by adjusting the number of parts by weight of the particles based on 100 parts by weight of the resin in the anti-glare layer forming material, the surface shape of the anti-glare film can be controlled (adjusted) over a wider range. You can also.

In addition, in the anti-glare film of the present invention, the convex portions may have a gentle shape to prevent the occurrence of protrusions on the surface of the anti-glare layer (B) that would cause defects in appearance. It is not limited to this. Further, in the anti-glare film of the present invention, some of the particles may be present, for example, at positions overlapping directly or indirectly in the thickness direction of the anti-glare layer (B).

The other layers are not particularly limited, and may be, for example, a low refractive index layer, a low reflection layer, a conductive layer, an antifouling layer, a high hardness layer, a high refractive index layer, a UV absorption layer, etc. as described above. good. Further, the other layer may be one layer or a plurality of layers, and in the case of a plurality of layers, one type or a plurality of types may be used. For example, the other layer may be an optical thin film whose thickness and refractive index are strictly controlled, or a stack of two or more optical thin films. Hereinafter, a case where the other layer is the low reflection layer (C) will be described.

For example, when an anti-glare film is attached to an image display device, one of the factors that reduces the visibility of images is the reflection of light at the interface between air and the anti-glare layer (B). The low reflection layer (C) can reduce surface reflection. The anti-glare layer (B) and the low-reflection layer (C) may be formed only on one surface of the light-transmitting substrate (A), or may be formed on both surfaces. Moreover, the antiglare layer (B) and the low reflection layer (C) may each have a multilayer structure in which two or more layers are laminated.

In the present invention, the low reflection layer (C) may be an optical thin film whose thickness and refractive index are strictly controlled, or a laminate of two or more of the optical thin films. The low reflection layer (C) exhibits an antireflection function by canceling out the opposite phases of incident light and reflected light using the interference effect of light. The wavelength range of visible light that exhibits the antireflection function is, for example, 380 to 780 nm, and the wavelength range with particularly high visibility is 450 to 650 nm, and the reflectance at the center wavelength of 550 nm is minimized. The low reflection layer (C) may be designed as follows.

In addition, for example, in order to prevent the adhesion of contaminants and to improve the ease of removing the adhered contaminants, a contamination prevention layer formed from a fluorine group-containing silane compound or a fluorine group-containing organic compound may be added to the above. It may be laminated on the low reflection layer (C).

[2. Manufacturing method of anti-glare film]
The method for producing the anti-glare film of the present invention is not particularly limited and may be produced by any method, but it is preferably produced by the method for producing the anti-glare film of the present invention.

The method for manufacturing the anti-glare film can be carried out, for example, as follows.

First, the anti-glare layer (B) is formed on the light-transmissive substrate (A) so as to satisfy the formulas (1) and (2) (anti-glare layer (B) forming step). Thereby, a laminate of the light-transmitting substrate (A) and the anti-glare layer (B) is manufactured. As described above, the anti-glare layer (B) forming step includes a coating step of coating a coating solution on the light-transmitting substrate (A), and a coating step of drying the coated coating solution. and a coating film forming step of forming a film. Furthermore, for example, as described above, the antiglare layer (B) forming step may further include a curing step of curing the coating film. The curing can be performed, for example, after the drying, but is not limited thereto. The curing can be performed by heating, light irradiation, etc., for example. The light is not particularly limited, and may be, for example, ultraviolet light. The light source for the light irradiation is also not particularly limited, and may be, for example, a high-pressure mercury lamp.

As described above, the coating liquid includes a resin and a solvent. The coating liquid may be, for example, an anti-glare layer forming material (coating liquid) containing the resin, the particles, the thixotropy imparting agent, and the solvent.

The coating liquid preferably exhibits thixotropic properties, and preferably has a Ti value defined by the following formula in the range of 1.3 to 3.5, more preferably 1.4 to 3. It is in the range of 2, more preferably in the range of 1.5 to 3.

Ti value = β1/β2

In the above formula, β1 is the viscosity measured at a shear rate of 20 (1/s) using Rheostress RS6000 manufactured by HAAKE, and β2 is the viscosity measured at a shear rate of 200 (1/s) using Rheostress RS6000 manufactured by HAAKE. This is the viscosity measured under the following conditions.

If the Ti value is 1.3 or more, problems such as appearance defects and deterioration of anti-glare properties and white blurring properties are unlikely to occur. Further, if the Ti value is 3.5 or less, problems such as the particles not agglomerating and becoming dispersed are less likely to occur.

Further, the coating liquid may or may not contain a thixotropy-imparting agent, but it is preferable to include a thixotropy-imparting agent because it tends to exhibit thixotropy. Further, as described above, when the coating liquid contains the thixotropy imparting agent, an effect of preventing sedimentation of the particles (thixotropic effect) can be obtained. Furthermore, by shear aggregation of the thixotropy imparting agent itself, it is also possible to freely control the surface shape of the antiglare film over a wider range. For example, when the coating liquid does not contain particles but contains a thixotropy agent, the antiglare film of the present invention can have small θa and Rz and smooth irregularities on the outermost surface, as described above. can. Furthermore, by including a thixotropy imparting agent and particles having a small particle size in the coating liquid, the antiglare film of the present invention having a small θa and Rz and a smooth unevenness on the outermost surface can be obtained. can do.

The solvent is not particularly limited, and various solvents can be used, and one type may be used alone or two or more types may be used in combination. Depending on the composition of the resin, the types and contents of the particles and the thixotropy-imparting agent, there is an optimal solvent type and solvent ratio in order to obtain the antiglare film of the present invention. Examples of the solvent include, but are not limited to, alcohols such as methanol, ethanol, isopropyl alcohol, butanol, and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclopentanone; methyl acetate, ethyl acetate. , esters such as butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, and octane. Aromatic hydrocarbons such as benzene, toluene, xylene, etc. Further, for example, the solvent may include a hydrocarbon solvent and a ketone solvent. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be, for example, at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene. The ketone solvent may be, for example, cyclopentanone and at least one selected from the group consisting of acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent at a mass ratio of 90:10 to 10:90. The mass ratio of the hydrocarbon solvent to the ketone solvent may be, for example, 80:20 to 20:80, 70:30 to 30:70, or 40:60 to 60:40. In this case, for example, the hydrocarbon solvent may be toluene, and the ketone solvent may be methyl ethyl ketone.

For example, when an acrylic film is used as the translucent base material (A) to form an intermediate layer (permeation layer), a good solvent for the acrylic film (acrylic resin) can be suitably used. The solvent may be, for example, a solvent containing a hydrocarbon solvent and a ketone solvent, as described above. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be, for example, at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene. The ketone solvent may be, for example, at least one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent at a mass ratio of 90:10 to 10:90. The mass ratio of the hydrocarbon solvent to the ketone solvent may be, for example, 80:20 to 20:80, 70:30 to 30:70, or 40:60 to 60:40. In this case, for example, the hydrocarbon solvent may be toluene, and the ketone solvent may be methyl ethyl ketone.

When forming an intermediate layer (permeation layer) using, for example, triacetyl cellulose (TAC) as the transparent substrate (A), a good solvent for TAC can be suitably used. Examples of the solvent include ethyl acetate, methyl ethyl ketone, and cyclopentanone.

In addition, by appropriately selecting the solvent, it is possible to make the anti-glare layer forming material (coating liquid) exhibit good thixotropy when it contains a thixotropy imparting agent. For example, when using organoclay, toluene and xylene can be preferably used alone or in combination; for example, when using oxidized polyolefin, methyl ethyl ketone, ethyl acetate, propylene glycol monomethyl ether can preferably be used alone. They can be used or used in combination. For example, when using modified urea, butyl acetate and methyl isobutyl ketone can be suitably used alone or in combination.

Various leveling agents can be added to the anti-glare layer forming material. As the leveling agent, for example, a fluorine-based or silicone-based leveling agent can be used for the purpose of preventing uneven coating (uniform coating surface). In the present invention, when antifouling properties are required on the surface of the anti-glare layer (B), or when a layer containing a low reflection layer (low refractive index layer) or an interlayer filler is provided on the anti-glare layer (B) as described below, The leveling agent can be selected as appropriate depending on the case where the layer is formed. In the present invention, for example, by including the thixotropy imparting agent, the coating liquid can exhibit thixotropy, so that coating unevenness is less likely to occur. In this case, for example, there is an advantage that the options for the leveling agent can be expanded.

The blending amount of the leveling agent is, for example, 5 parts by weight or less, preferably in the range of 0.01 to 5 parts by weight, based on 100 parts by weight of the resin.

If necessary, pigments, fillers, dispersants, plasticizers, ultraviolet absorbers, surfactants, antifouling agents, antioxidants, etc. may be added to the anti-glare layer forming material within a range that does not impair performance. may be done. These additives may be used alone or in combination of two or more.

For the anti-glare layer forming material, a conventionally known photopolymerization initiator as described in JP-A No. 2008-88309, for example, can be used.

Examples of the method for forming a coating film by coating the coating liquid on the light-transmitting substrate (A) include fountain coating, die coating, spin coating, spray coating, and gravure coating. Coating methods such as , roll coating, bar coating, etc. can be used.

Next, as described above, the coating film is dried and cured to form an anti-glare layer (B). The drying may be, for example, natural drying, air drying by blowing wind, heat drying, or a combination of these methods.

The drying temperature of the coating liquid for forming the antiglare layer (B) may be, for example, in the range of 30 to 200°C. The drying temperature may be, for example, 40°C or higher, 50°C or higher, 60°C or higher, 70°C or higher, 80°C or higher, 90°C or higher, or 100°C or higher, 190°C or lower, 180°C or lower, or 170°C or lower. It may be below 160°C, below 150°C, below 140°C, below 135°C, below 130°C, below 120°C, or below 110°C. The drying time is not particularly limited, but may be, for example, 30 seconds or more, 40 seconds or more, 50 seconds or more, or 60 seconds or more, and 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less. It's okay.

The means for curing the coating film is not particularly limited, but ultraviolet curing is preferred. The irradiation amount of the energy ray source is preferably 50 to 500 mJ/cm ² as a cumulative exposure amount at an ultraviolet wavelength of 365 nm. When the irradiation amount is 50 mJ/cm ² or more, curing is likely to proceed sufficiently, and the hardness of the anti-glare layer (B) to be formed is likely to be high. Moreover, if it is 500 mJ/cm ² or less, coloring of the anti-glare layer (B) to be formed can be prevented.

In the manner described above, a laminate of the light-transmitting substrate (A) and the anti-glare layer (B) can be manufactured. This laminate may be used as the anti-glare film of the present invention as it is, or, for example, the other layer may be formed on the anti-glare layer (B) to provide the anti-glare film of the present invention. The method for forming the other layer is not particularly limited, and can be performed, for example, by a method similar to or similar to a general method for forming a low refractive index layer, a low reflection layer, and the like. Below, the process of forming the low reflective layer (C) (low reflective layer forming process) when the other layer is the low reflective layer (C) will be described.

First, a low reflection layer forming coating liquid for forming the low reflection layer (C) is prepared. The coating liquid for forming a low reflection layer may contain, for example, a resin, a fluorine element-containing additive, hollow particles, solid particles, a diluent solvent, etc., and can be produced, for example, by mixing these.

Examples of the resin include thermosetting resins and ionizing radiation-curable resins that are cured by ultraviolet light or light. As the resin, it is also possible to use commercially available thermosetting resins, ultraviolet curable resins, and the like.

As the thermosetting resin or the ultraviolet curable resin, for example, a curable compound having at least one of an acrylate group and a methacrylate group that is cured by heat, light (such as ultraviolet rays), or electron beam, etc. can be used, for example, Silicone resins, polyester resins, polyether resins, epoxy resins, urethane resins, alkyd resins, spiroacetal resins, polybutadiene resins, polythiol polyene resins, oligomers or prepolymers such as acrylates and methacrylates of polyfunctional compounds such as polyhydric alcohols, etc. can give. These may be used alone or in combination of two or more.

For example, a reactive diluent having at least one of an acrylate group and a methacrylate group can also be used in the resin. The reactive diluent can be, for example, the reactive diluent described in JP-A No. 2008-88309, and includes, for example, monofunctional acrylate, monofunctional methacrylate, polyfunctional acrylate, polyfunctional methacrylate, and the like. As the reactive diluent, trifunctional or higher functional acrylates or trifunctional or higher functional methacrylates are preferred. This is because the hardness of the low reflection layer (C) can be made excellent. Examples of the reactive diluent include butanediol glycerol ether diacrylate, isocyanuric acid acrylate, isocyanuric acid methacrylate, and the like. These may be used alone or in combination of two or more. The weight average molecular weight of the resin before curing may be, for example, 100 or more, 300 or more, 500 or more, 1,000 or more, or 2,000 or more, and 100,000 or less, 70,000 or less, 50 or more. ,000 or less, 30,000 or less, or 10,000 or less. If the weight average molecular weight before curing is high, the hardness will be reduced, but cracking will tend to be less likely to occur when bent. On the other hand, if the weight average molecular weight before curing is low, the intermolecular crosslink density tends to improve and the hardness tends to increase.

For example, a curing agent may be added to cure the curable resin. The curing agent is not particularly limited, and for example, known polymerization initiators (eg, thermal polymerization initiators, photopolymerization initiators, etc.) can be used as appropriate. The amount of the curing agent added is not particularly limited, but for example, 0.5 parts by weight or more, 1.0 parts by weight or more, 1.5 parts by weight, based on 100 parts by weight of the resin in the coating liquid for forming a low reflection layer. It may be at least 15 parts by weight, at least 13 parts by weight, at most 10 parts by weight, at most 7 parts by weight, or at most 5 parts by weight. There may be.

The fluorine element-containing additive is not particularly limited, but may be, for example, an organic compound or an inorganic compound containing fluorine in its molecule. The organic compound is not particularly limited, and examples thereof include fluorine-containing antifouling coating agents, fluorine-containing acrylic compounds, fluorine- and silicon-containing acrylic compounds, and the like. Specific examples of the organic compound include "KY-1203" and "KY-100" manufactured by Shin-Etsu Chemical Co., Ltd., and "Megafac" manufactured by DIC Corporation. The inorganic compound is also not particularly limited. The amount of the fluorine element-containing additive added is not particularly limited, but for example, the weight of the fluorine element in the solid content is, for example, relative to the weight of the entire solid content in the coating liquid for forming a low reflection layer. It may be 0.05% by weight or more, 0.1% by weight or more, 0.15% by weight or more, 0.20% by weight or more, or 0.25% by weight or more, and 20% by weight or less, 15% by weight or less , 10% by weight or less, 5% by weight or less, or 3% by weight or less. Furthermore, for example, the weight of the fluorine element-containing additive is, for example, 0.05% by weight or more, 0.1% by weight or more, 0. .15% by weight or more, 0.20% by weight or more, or 0.25% by weight or more, and 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 3% by weight. The following may be sufficient. From the viewpoint of the scratch resistance of the low reflection layer (C), it is preferable that the amount of the fluorine element-containing additive added is neither too large nor too small.

The hollow particles are not particularly limited, and may be, for example, silica particles, acrylic particles, acrylic-styrene copolymer particles, or the like. Examples of the silica particles include products such as "Surulia 5320" and "Surulia 4320" manufactured by JGC Catalysts & Chemicals Co., Ltd. The weight average particle diameter of the hollow particles is not particularly limited, but may be, for example, 30 nm or more, 40 nm or more, 50 nm or more, 60 nm or more, or 70 nm or more, 150 nm or less, 140 nm or less, 130 nm or less, 120 nm or less, Or it may be 110 nm or less. The shape of the hollow particles is not particularly limited, and may be, for example, approximately spherical in the shape of a bead, or irregularly shaped such as powder, but is preferably approximately spherical, and more preferably, The particles are approximately spherical particles with an aspect ratio of 1.5 or less, and most preferably spherical particles. By adding the hollow particles, it is possible to achieve, for example, a low refractive index and good antireflection properties of the low reflection layer (C). The amount of the hollow particles added is not particularly limited, but for example, 30 parts by weight or more, 50 parts by weight or more, 70 parts by weight or more, 90 parts by weight based on 100 parts by weight of the resin in the coating liquid for forming a low reflection layer. parts or more, or 100 parts by weight or more, and 300 parts by weight or less, 270 parts by weight or less, 250 parts by weight or less, 200 parts by weight or less, or 180 parts by weight or less. From the viewpoint of lowering the refractive index of the low-reflection layer (C), it is preferable that the amount of the hollow particles added is not too small, and from the viewpoint of ensuring the mechanical properties of the low-reflection layer (C), the addition of the hollow particles It is preferable that the amount is not too large.

The solid particles are not particularly limited, and may be, for example, silica particles, zirconium oxide particles, titanium-containing particles (eg, titanium oxide particles), or the like. Examples of the silica particles include products such as "MEK-2140Z-AC", "MIBK-ST", and "IPA-ST" manufactured by Nissan Chemical Industries, Ltd. The weight average particle diameter of the solid particles is not particularly limited, but may be, for example, 5 nm or more, 10 nm or more, 15 nm or more, 20 nm or more, or 25 nm or more, and 3300 nm or less, 250 nm or less, 200 nm or less, or 150 nm or less. , or 100 nm or less. The shape of the solid particles is not particularly limited, and may be, for example, approximately spherical in the form of beads, or irregularly shaped such as powder, but approximately spherical is preferred, and more preferably , substantially spherical particles with an aspect ratio of 1.5 or less, and most preferably spherical particles. By adding the solid particles, for example, the fluorine element-containing additive is likely to be unevenly distributed on the surface of the applied coating liquid for forming a low reflection layer, thereby improving the scratch resistance of the low reflection layer (C). becomes more sexual. A low refractive index, good antireflection properties, etc. of the low reflection layer (C) can be achieved. The amount of the solid particles added is not particularly limited, but is, for example, 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, 20 parts by weight or more, based on 100 parts by weight of the resin in the coating liquid for forming a low reflection layer. It may be at least 25 parts by weight, or at most 150 parts by weight, at most 120 parts by weight, at most 100 parts by weight, or at most 80 parts by weight. From the viewpoint of ensuring mechanical properties and adjusting the refractive index, it is preferable that the amount of the solid particles added is not too small, and from the viewpoint of preventing clouding of the coating film due to scattering, the amount of the solid particles added is not too large. It is preferable.

The diluent solvent is not particularly limited, and various solvents can be used, and one type may be used alone or two or more types may be used in combination. Examples of the diluting solvent include alcohols such as methanol, ethanol, isopropyl alcohol, butanol, TBA (tertiary butyl alcohol), and 2-methoxyethanol; acetone, methyl ethyl ketone, MIBK (methyl isobutyl ketone), and cyclopentanone. Ketones; Esters such as methyl acetate, ethyl acetate, butyl acetate, and PMA (propylene glycol monomethyl ether acetate); Ethers such as diisopropyl ether and propylene glycol monomethyl ether; Glycols such as ethylene glycol and propylene glycol; Ethyl cellosolve, Examples include cellosolves such as butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, and octane; and aromatic hydrocarbons such as benzene, toluene, and xylene. For example, the polarity of the diluting solvent may be adjusted by mixing a plurality of solvents at an arbitrary ratio.

The diluent solvent may be, for example, a mixed solvent containing MIBK (methyl isobutyl ketone) and PMA (propylene glycol monomethyl ether acetate). The mixing ratio in this case is not particularly limited, but when the weight of MIBK is 100% by weight, the weight of PMA is, for example, 20% by weight or more, 50% by weight or more, 100% by weight or more, 150% by weight or more, or It may be 200% by weight or more, 400% by weight or less, 350% by weight or less, 300% by weight or less, or 250% by weight or less.

The diluent solvent may be, for example, a mixed solvent containing TBA (tertiary butyl alcohol) in addition to MIBK and PMA. The mixing ratio in this case is not particularly limited, but when the weight of MIBK is 100% by weight, the weight of PMA is, for example, 10% by weight or more, 30% by weight or more, 50% by weight or more, 80% by weight or more, or It may be 100% by weight or more, 200% by weight or less, 180% by weight or less, 150% by weight or less, 130% by weight or less, or 110% by weight or less. Furthermore, when the weight of MIBK is 100% by weight, the weight of TBA may be, for example, 10% by weight or more, 30% by weight or more, 50% by weight or more, 80% by weight or more, or 100% by weight or more. , 200% by weight or less, 180% by weight or less, 150% by weight or less, 130% by weight or less, or 110% by weight or less.

The amount of the diluting solvent added is not particularly limited either, but for example, the solid content relative to the weight of the entire coating solution for forming a low reflection layer is, for example, 0.1% by weight or more, 0.3% by weight or more, 0.1% by weight or more, 0.3% by weight or more, or 0.3% by weight or more. It may be 5% by weight or more, 1.0% by weight or more, or 1.5% by weight or more, and 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 3% by weight. % or less. From the viewpoint of ensuring coating properties (wetting, leveling), it is preferable that the solid content is not too high, and from the viewpoint of preventing appearance defects caused by drying such as air drying unevenness and whitening, the solid content is preferably not too low.

Next, the coating liquid for forming a low reflection layer is applied onto the anti-glare layer (B) (the coating step). The coating method is not particularly limited, and for example, known coating methods such as fountain coating, die coating, spin coating, spray coating, gravure coating, roll coating, and bar coating may be used as appropriate. can. The coating amount of the coating liquid for forming a low reflection layer is also not particularly limited, but the thickness of the low reflection layer (C) to be formed is, for example, 0.1 μm or more, 0.3 μm or more, 0.5 μm or more, It may be 1.0 μm or more, or 2.0 μm or more, or it may be 50 μm or less, 40 μm or less, 30 μm or less, 20 μm or less, or 10 μm or less.

Next, the applied coating solution for forming a low reflection layer is dried to form a coating film (the coating film forming step). The drying temperature is not particularly limited, and may be, for example, in the range of 30 to 200°C. The drying temperature may be, for example, 40°C or higher, 50°C or higher, 60°C or higher, 70°C or higher, 80°C or higher, 90°C or higher, or 100°C or higher, 190°C or lower, 180°C or lower, or 170°C or lower. It may be below 160°C, below 150°C, below 140°C, below 135°C, below 130°C, below 120°C, or below 110°C. The drying time is not particularly limited, but may be, for example, 30 seconds or more, 40 seconds or more, 50 seconds or more, or 60 seconds or more, and 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less. It's okay.

Furthermore, the coating film may be cured (curing step). The curing can be performed by heating, light irradiation, etc., for example. The light is not particularly limited, and may be, for example, ultraviolet light. The light source for the light irradiation is also not particularly limited, and may be, for example, a high-pressure mercury lamp. The irradiation amount of the energy ray source in the ultraviolet curing is preferably 50 to 500 mJ/cm ² as a cumulative exposure amount at an ultraviolet wavelength of 365 nm. When the irradiation amount is 50 mJ/cm ² or more, curing is likely to proceed sufficiently, and the hardness of the formed low-reflection layer (C) is likely to be high. Moreover, if it is 500 mJ/cm ² or less, coloring of the low reflection layer (C) to be formed can be prevented.

As described above, the anti-reflection layer of the present invention has the anti-glare layer (B) and the low-reflection layer (C) laminated in the above-mentioned order on at least one surface of the light-transmitting substrate (A). Film can be manufactured. Note that, as described above, the antireflection film of the present invention may contain layers other than the light-transmitting substrate (A), the anti-glare layer (B), and the low-reflection layer (C). .

Moreover, in the manufacturing process of the antireflection film of the present invention, it is preferable to perform a surface treatment on at least one of the light-transmitting substrate (A) and the anti-glare layer (B). If the surface of the light-transmitting substrate (A) is subjected to a surface treatment, the adhesion to the anti-glare layer (B) or the polarizer or polarizing plate is further improved. Further, if the surface of the anti-glare layer (B) is subjected to a surface treatment, the adhesion with the low-reflection layer (C) is further improved.

[3. Optical members and image display devices]
The optical member of the present invention is not particularly limited, but may be, for example, a polarizing plate. The polarizing plate is also not particularly limited, but may include, for example, the antiglare film and polarizer of the present invention, and may further include other components. Each component of the polarizing plate may be bonded together using, for example, an adhesive or a pressure-sensitive adhesive.

The image display device of the present invention is not particularly limited, and may be any image display device, including, for example, a liquid crystal display device, an organic EL display device, and the like.

The image display device of the present invention is, for example, an image display device having the anti-glare film of the present invention on the viewing side surface, and the image display device may have a black matrix pattern.

The anti-glare film of the present invention can be bonded, for example, to an optical member used in an LCD via a pressure-sensitive adhesive or an adhesive on the light-transmitting substrate (A) side. In addition, in this bonding, the surface of the light-transmitting substrate (A) may be subjected to various surface treatments as described above. As described above, according to the method for producing an anti-glare film of the present invention, the surface shape of the anti-glare film can be freely controlled over a wide range. Therefore, the optical properties that can be obtained by laminating the anti-glare film with other optical members using an adhesive or adhesive can be obtained over a wide range depending on the surface shape of the anti-glare film. .

Examples of the optical member include a polarizer or a polarizing plate. A polarizing plate generally has a structure in which a transparent protective film is provided on one or both sides of a polarizer. When providing transparent protective films on both sides of the polarizer, the front and back transparent protective films may be made of the same material or may be made of different materials. Polarizing plates are typically placed on both sides of the liquid crystal cell. Moreover, the polarizing plates are arranged so that the absorption axes of the two polarizing plates are substantially orthogonal to each other.

The structure of the polarizing plate in which the anti-glare film is laminated is not particularly limited, but for example, a structure in which a transparent protective film, the polarizer, and the transparent protective film are laminated in this order on the anti-glare film. Alternatively, the polarizer and the transparent protective film may be laminated in this order on the anti-glare film.

The image display device of the present invention has the same configuration as a conventional image display device except that the anti-glare film is arranged in a specific direction. For example, in the case of an LCD, it can be manufactured by appropriately assembling each component such as a liquid crystal cell, optical members such as a polarizing plate, and, if necessary, a lighting system (such as a backlight), and incorporating a drive circuit.

The image display device of the present invention may be used for any appropriate purpose. Applications include, for example, computer monitors, notebook computers, office equipment such as copy machines, mobile phones, watches, digital cameras, personal digital assistants (PDAs), portable devices such as portable game consoles, video cameras, televisions, microwave ovens, etc. household electrical equipment, rear view monitors, car navigation system monitors, in-vehicle equipment such as car audio, exhibition equipment such as information monitors for commercial stores, security equipment such as surveillance monitors, nursing care monitors, medical monitors, etc. Nursing care/medical equipment, etc.

Next, examples of the present invention will be described together with comparative examples. However, the present invention is not limited to the following examples and comparative examples.

In addition, in the following Examples and Comparative Examples, parts of substances are parts by mass (parts by weight) unless otherwise specified.

[Coating liquid 1: Anti-glare layer forming material]
The main components of the resin contained in the anti-glare layer are 40 parts by weight of urethane acrylate prepolymer (manufactured by Shin Nakamura Chemical Co., Ltd., trade name "UA-53H-80BK", solid content 80%) and pentaerythol triacrylate. 60 parts by weight of a polyfunctional acrylate (manufactured by Osaka Organic Chemical Industry Co., Ltd., trade name "Viscoat #300", solid content 100%) was prepared. Per 100 parts by weight of the resin solid content of the resin, 1.2 parts by weight of synthetic smectite (manufactured by Co-op Chemical Co., Ltd., trade name "Lucentite SAN"), which is an organic clay, as a thixotropy imparting agent, and a photopolymerization initiator (BASF). 5 parts by weight of Irgacure 907 (manufactured by Kyoeisha Chemical Co., Ltd., trade name) and 0.15 parts by weight of a leveling agent (manufactured by Kyoeisha Chemical Co., Ltd., trade name "LE-303", solid content 40%) were mixed. The organic clay was diluted with toluene to have a solid content of 6% by weight. This mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration was 40% by weight, and an anti-glare layer forming material ( Coating liquid 1) was prepared.

[Coating liquid 2: low reflection layer forming material]
Prepare 100 parts by weight of a polyfunctional acrylate (manufactured by Osaka Organic Chemical Industry Co., Ltd., trade name "Viscoat #300", solid content 100%) containing pentaerythritol triacrylate as the main component as a resin included in the low reflection layer. did. Per 100 parts by weight of resin solid content of the resin, 30 parts by weight of organosilica sol (particle size 10 to 15 nm), 100 parts by weight hollow silica particles (weight average particle size 75 nm), photopolymerization initiator (manufactured by BASF, trade name: A total of 10 parts by weight of ``Irgacure 907'' and ``Irgacure 2959'') and 10 parts by weight of a radical-reactive group-containing fluorine-based antifouling additive were mixed. This mixture was diluted with a mixed solvent of methyl isobutyl ketone/propylene glycol monomethyl ether acetate (weight ratio 25/75) so that the solid content concentration was 1.5% by weight, and a low A reflective layer forming material (coating liquid 2) was prepared.

[Coating liquid 3: anti-glare layer forming material]
Coating liquid 1 was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration was 42% by weight to prepare an anti-glare layer forming material (coating liquid 3). .

[Coating liquid 4: Anti-glare layer forming material]
0.5 parts by weight of inorganic particles (Sekisui Plastics Co., Ltd., product name "Techpolymer SSX-103DXE" weight average particle diameter 3.0 μm) were mixed into 1 part of the coating solution per 100 parts by weight of resin solid content. , a mixture was obtained. The mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration was 42% by weight to prepare an anti-glare layer forming material (coating liquid 4).

[Coating liquid 5: anti-glare layer forming material]
Coating liquid 1 was diluted with toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration was 38% by weight to prepare an anti-glare layer forming material (coating liquid 3). .

[Coating liquid 6: Anti-glare layer forming material]
Coating liquid 1 was mixed with 0.5 parts by weight of inorganic particles (Sekisui Plastics Co., Ltd., product name: "Techpolymer SSX-103DXE") per 100 parts by weight of resin solid content to obtain a mixture. The mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration was 40% by weight to prepare an anti-glare layer forming material (coating liquid 6).

[Coating liquid 7: Anti-glare layer forming material]
Coating liquid 1 was mixed with 0.5 parts by weight of inorganic particles (Sekisui Plastics Co., Ltd., product name: "Techpolymer SSX-103DXE") per 100 parts by weight of resin solid content to obtain a mixture. The mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration was 38% by weight to prepare an anti-glare layer forming material (coating liquid 6).

[Example 1]
An antiglare film was produced as follows.

As the translucent substrate (A), a transparent plastic film substrate (acrylic film, manufactured by Toyo Kohan Co., Ltd., trade name "HX-40UC", thickness: 40 μm, refractive index: 1.50) was prepared. . The anti-glare layer forming material (coating liquid 1) was applied to one side of the transparent plastic film substrate using a wire bar to form a coating film (coating step). The coating film was then dried by heating at 100° C. for 1 minute (drying step). Thereafter, the coating film was cured by irradiating ultraviolet rays with a cumulative light intensity of 300 mJ/cm ² using a high-pressure mercury lamp to form an anti-glare layer (B) with a thickness of 6.5 μm. The anti-glare layer (B) in the anti-glare film of this example is an anti-glare hard coat layer. The same applies to all Examples and Comparative Examples below.

Further, the low reflection layer forming material (coating liquid 2) was applied onto the anti-glare layer (B) using a spin coater to form a coating film (coating step). The coating film was then dried by heating at 90° C. for 1 minute (drying step). Thereafter, the coating film was cured by irradiating ultraviolet rays with a cumulative light intensity of 300 mJ/cm ² using a high-pressure mercury lamp to form a low reflection layer (C) with a thickness of 100 nm, thereby obtaining the anti-glare film of this example. Ta.

[Example 2]
An antiglare film was produced in the same manner as in Example 1 except that Coating Solution 3 was used instead of Coating Solution 1 as the antiglare layer forming material.

[Example 3]
An antiglare film was produced in the same manner as in Example 1 except that Coating Solution 4 was used instead of Coating Solution 1 as the antiglare layer forming material.

[Example 4]
An antiglare film was produced in the same manner as in Example 1 except that Coating Solution 5 was used instead of Coating Solution 1 as the antiglare layer forming material.

[Example 5]
An antiglare film was produced in the same manner as in Example 1 except that the thickness (film thickness) of the antiglare layer (B) was 8.5 μm.

[Example 6]
Same as Example 1 except that coating liquid 6 was used instead of coating liquid 1 as the anti-glare layer forming material and the thickness (film thickness) of the anti-glare layer (B) was formed to 5.0 μm. An antiglare film was produced in the same manner.

[Example 7]
An antiglare film was produced in the same manner as in Example 1 except that the low reflection layer (C) was not formed on the antiglare layer (B).

[Comparative example 1]
An antiglare film was produced in the same manner as in Example 1 except that Coating Solution 6 was used instead of Coating Solution 1 as the antiglare layer forming material.

[Comparative example 2]
Same as Example 1 except that coating liquid 6 was used instead of coating liquid 1 as the anti-glare layer forming material, and the thickness (film thickness) of the anti-glare layer (B) was formed to 8.5 μm. An antiglare film was produced in the same manner.

[Comparative example 3]
An antiglare film was produced in the same manner as in Example 1 except that Coating Solution 7 was used in place of Coating Solution 1 as the antiglare layer forming material.

[Comparative example 4]
An antiglare film was produced in the same manner as in Comparative Example 1 except that the low reflection layer (C) was not formed on the antiglare layer (B).

Regarding the anti-glare films of Examples 1 to 7 and Comparative Examples 1 to 4 produced as described above, the outermost surface on the anti-glare layer (B) side (anti-glare layer (B) surface or low Measure or Calculated.

[Measurement and calculation method of uneven shape]
In accordance with JIS B0601 (1994 edition), the average distance between concavo-convex portions Sm (mm), ten-point average height Rz (μm), and arithmetic mean surface roughness Ra (μm) of the outermost surface of the anti-glare film were measured. Specifically, first, a glass plate (manufactured by MATSUNAMI, MICRO SLIDE GLASS, product number S, thickness 1 .3 mm, 45 x 50 mm) were pasted together with an adhesive to prepare a sample. Next, a stylus-type surface roughness measuring device (manufactured by Kosaka Laboratory Co., Ltd., high-precision micro-shape measuring device, product name “Surfcoder ET4000”) with a measuring needle with a radius of curvature R = 2 μm at the tip (diamond) ) under the conditions of a scanning speed of 1 mm/sec, a cutoff value of 0.8 mm, and a measurement length of 12 mm. C) The uneven shape of the surface) was measured in a certain direction. Based on this measurement, the average distance between concavities and convexities Sm (mm), the ten-point average height Rz, and the arithmetic mean surface roughness Ra of the outermost surface were calculated. Furthermore, the average inclination angle θa (°) was calculated from the surface roughness curve obtained based on the measured values (calculated values). Note that the high-precision fine shape measuring device automatically calculates each of the measured values.

Furthermore, regarding the antiglare films of Examples 1 to 7 and Comparative Examples 1 to 4, suppression of white haze generation was determined (evaluated) by the following method.

[White haze determination method]
(1) A black acrylic plate (manufactured by Mitsubishi Rayon Co., Ltd., thickness 2.0 mm) is attached to the surface of the light-transmissive base material (A) of the anti-glare film on which the anti-glare layer (B) is not formed. A sample was created by bonding the two together to eliminate reflection on the back side.
(2) In an office environment where a display is generally used (approximately 1000 Lx), the sample was illuminated with a fluorescent lamp (three wavelength light source), and the white haze of the sample was visually determined according to the following criteria.

Judgment criteria
OK: The wavy color difference between black and white is not visible, or the color difference is so weak that it poses no practical problem.
NG: A wavy color difference between black and white is visible.

The uneven shapes of the outermost surfaces of the antiglare films of Examples 1 to 7 and Comparative Examples 1 to 4 and the white haze determination results are summarized in Table 1 below.

As shown in Table 1, white haze was suppressed in the antiglare films of Examples 1 to 7 that satisfied θa≦0.24 and Rz≦0.20. On the other hand, the antiglare films of Comparative Examples 1 to 4, which did not satisfy either θa≦0.24 and Rz≦0.20, had insufficient suppression of white haze. Regarding anti-glare properties, all of the anti-glare films of Examples 1 to 7 were able to prevent the outline image of the fluorescent lamp from being reflected under the conditions of the white haze determination method, so there was no problem in practical use. It was at an unprecedented level.

As described above, according to the present invention, it is possible to provide an anti-glare film, a method for manufacturing an anti-glare film, an optical member, and an image display device in which the occurrence of white mist is suppressed. The application of the present invention is not particularly limited and can be used in a wide range of applications, for example, it can be applied to any image display device.

10 Anti-glare film 11 Light-transmitting base material (A)
12 Anti-glare layer (B)
12a Resin layer 12b Particles 12c Thixotropy imparting agent 13 Low reflection layer (C) (other layers)

Claims (14)

An anti-glare film in which an anti-glare layer (B) is laminated on a light-transparent substrate (A),
The anti-glare layer (B) contains particles, the particle diameter (D) (weight average particle diameter) of the particles is within the range of 2 to 10 μm,
Irregularities are formed on the outermost surface of the anti-glare layer (B) side of the anti-glare film,
An anti-glare film characterized in that the unevenness satisfies the following formulas (1) and (2).

0.15≦θa≦0.24 (1)
0.17≦Rz≦0.20 (2)

In the formula (1), θa is the average inclination angle [°] of the unevenness,
In the formula (2), Rz is the ten-point average height [μm] of the unevenness. The anti-glare film according to claim 1, which further satisfies the following formula (3).

Ra≦0.050 (3)

In the formula (3), Ra is the arithmetic mean surface roughness [μm] of the unevenness. On the surface of the anti-glare layer (B) opposite to the light-transmitting base material (A), another layer other than the light-transmitting base material (A) and the anti-glare layer (B) is further provided. The antiglare film according to claim 1 or 2, which is laminated. An anti-glare product in which an anti-glare layer (B) and a layer other than the light-transparent base material (A) and the anti-glare layer (B) are laminated in the above order on a light-transparent base material (A). It is a sexual film,
The anti-glare layer (B) contains particles, the particle diameter (D) (weight average particle diameter) of the particles is within the range of 2 to 10 μm,
unevenness is formed on the outermost surface of the other layer,
An anti-glare film characterized in that the unevenness satisfies the following formulas (1) and (2).

0.15≦θa≦0.24 (1)
0.17≦Rz≦0.20 (2)

In the formula (1), θa is the average inclination angle [°] of the unevenness,
In the formula (2), Rz is the ten-point average height [μm] of the unevenness. The antiglare film according to claim 3 or 4, wherein the other layer is a low reflection layer (C). The antiglare film according to any one of claims 1 to 5, wherein the antiglare layer (B) contains a binder resin and a cohesive filler. The antiglare film according to claim 6, wherein the cohesive filler is an organic clay. A method for producing an anti-glare film, comprising:
The anti-glare film produced is the anti-glare film according to any one of claims 1 to 7 ,
an anti-glare layer (B) forming step of forming the anti-glare layer (B) on the light-transmissive substrate (A); , an unevenness forming step of forming the unevenness so as to satisfy the formulas (1) and (2),
The anti-glare layer (B) forming step includes a coating step of coating a coating solution on the light-transmitting substrate (A), and drying the applied coating solution to form a coating film. including a coating film forming step,
A manufacturing method characterized in that the coating liquid contains a resin, a solvent , and the particles . The manufacturing method according to claim 8 , wherein the anti-glare layer (B) forming step further includes a curing step of curing the coating film. The manufacturing method according to claim 8 or 9 , wherein the solvent contains toluene and methyl ethyl ketone. The anti-glare film is the anti-glare film according to any one of claims 3 to 5,
8. The unevenness forming step includes another layer forming step of forming a layer other than the light-transmitting base material (A) and the anti-glare layer (B) on the anti-glare layer (B). 10. The manufacturing method according to any one of 10 to 10 . An optical member comprising the antiglare film according to any one of claims 1 to 7 . The optical member according to claim 12 , which is a polarizing plate. An image display device comprising the anti-glare film according to any one of claims 1 to 7 or the optical member according to claim 12 or 13 .

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