JPH09254332A - Plastic substrate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a plastic substrate capable of being processed smoothly by a roll to roll system even though a surface B is not covered by a masking film by a method wherein a special design is applied to a surface structure of the surface (surface B) opposed to a transparent electrode formed surface (surface A) of the plastic substrate. SOLUTION: An outer layer to a surface A side of a plastic substrate 1 is composed of a setting resin set material layer 11. An outer layer to a surface B side is composed of a setting resin set material layer 12. At least one layer of an anti-gas permeability layer 13 exists to an inner side put between those both outer layers. Further, a surface of the setting resin set material layer 11 to the surface A side is formed smooth, and a surface of the setting resin set material layer 12 to the surface B side is formed in a fine round irregular surface. An SiOx (1.2<x<2) layer is preferably formed to at least one outer side of the setting resin set material layers 11, 12.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an easy-to-handle plastic substrate suitable for use as an electrode substrate for liquid crystal display panels.

[0002]

Conventionally, glass has been used as an electrode substrate for a liquid crystal display panel (that is, a substrate of a liquid crystal cell), but it is heavy, cannot be thinned, is easily damaged, and is mass-produced. Due to problems such as difficulty, plastic substrates have become popular recently.

The applicant of the present invention has filed numerous applications in the past as a plastics substrate manufacturer. Typical examples of the layer structure of the plastics substrate at this time are (a) polycarbonate film, polysulfone film, polyethersulfone film. A base film such as a polyarylate film having air-permeable resin layers provided on both sides thereof, and a curable resin cured product layer further provided on these air-permeable resin layers, (b) using a base film In this case, both outer layers are each composed of a curable resin cured product layer, and an air-permeable resin layer is provided on the inner side sandwiched between these outer layers. In the latter case (b), in order to obtain a glass-like rigidity, a curable resin cured product layer may be further provided on the inner side sandwiched between both outer layers together with the air permeation resistant resin layer.

Regardless of whether a base film is used or not, a preferable construction of the plastics substrate is such that both outer layers are composed of a curable resin cured product layer, and at least one layer is provided on the inner side sandwiched by both outer layers. This is a structure having the air-permeable layer of.

On one surface of the substrate having such a layer structure, I
A liquid crystal cell is manufactured by an ordinary method by arranging two transparent electrodes such as TO with the transparent electrode forming surfaces facing each other. Then, a phase plate or a polarizing plate is attached to the liquid crystal cell to manufacture a liquid crystal display panel. The structure of a typical liquid crystal display panel is polarizing plate / liquid crystal cell / polarizing plate or polarizing plate / phase plate / liquid crystal cell / polarizing plate.

[0006]

A plastics substrate in which both outer layers are composed of a curable resin cured product layer and at least one air permeation resistant layer is provided on the inner side sandwiched between the both outer layers is It can be wound into a roll and used for undercoating, forming ITO, assembling a liquid crystal display panel by a roll-to-roll method. However, if both surfaces of the plastics substrate are smooth, troubles such as running troubles occur due to lack of slipperiness in these steps.

Therefore, the slightly tacky surface of a semitransparent matte polyethylene film masking film (cover film), one surface of which has a slight tackiness and the other surface of which is roughened in a concavo-convex shape, is replaced by a plastic. The transparent substrate is adhered to the surface (B surface) opposite to the transparent electrode formation surface (A surface) to secure the necessary slipperiness.

When handling a plastic substrate, a masked B is used to improve quality and reliability.
SiOx (1.2 <x <2) by surface sputtering
Applicant believes that processing is performed. At this time, of course, once the masking film is peeled off, the Si
It is necessary to perform Ox treatment and then attach the masking film again after the treatment. In addition, when a polarizing plate or a phase plate is attached to the B side using an adhesive for the assembly of the liquid crystal display panel, it is naturally necessary to peel off the masking film. Furthermore, in providing a transparent electrode such as ITO on the A surface side of the plastic substrate, in many cases, the A surface is SiO 2 prior to the ITO treatment.
It is necessary to undercoat with x (x = 1.2 to 2), but the heat resistance of the polyethylene film masking film on the B side, which is the opposite side, is poor. A coat may be applied, and a masking film may be attached again after the undercoat.

However, the above-mentioned masking film sticking method requires an extra step for peeling and re-coating the masking film, is apt to generate an electric charge when the masking film is peeled off, and runs the plastics substrate during running. Wrinkles tend to wrinkle on the masking film where it comes into contact with the roll surface, and air enters the wrinkles, which easily causes troubles such as poor running and winding, and when the masking film made of polyethylene film is exposed to high temperatures. There are problems such as stickiness, which has been a problem to be solved at the manufacturing site of liquid crystal display panels. There is also a disadvantage that the cost is increased by the amount of the masking film installed.

Under such a background, the present invention adds a special device to the surface structure of the surface (B surface) opposite to the transparent electrode formation surface (A surface) of the plastics substrate, so that the B Even if you do not cover the surface with a masking film,
An object of the present invention is to provide a plastic substrate that can be smoothly handled by a roll-to-roll method.

[0011]

The plastics substrate of the present invention has a surface on the side of the plastics substrate (1) on which a transparent electrode is formed, named A surface, and a surface on the opposite side, named B surface. The outer layer on the side A of the substrate (1) is a cured resin layer (1
1), and the outer layer on the B side is a curable resin cured product layer (12)
And at least one air-permeable layer (13) is present on the inner side sandwiched between these outer layers, and the surface of the curable resin cured product layer (11) on the A side is smooth. It is characterized in that the surface of the curable resin cured product layer (12) formed and on the side B is formed into a fine and round uneven surface.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below. In this specification, the surface of the plastics substrate (1) on which the transparent electrode is formed is named surface A, and the opposite surface is named surface B.

Plastics substrate in the present invention (1)
The outer layer on the A side is composed of the curable resin cured material layer (11), the outer layer on the B surface side is composed of the curable resin cured material layer (12), and the inner side sandwiched between these outer layers. Has at least one air permeation resistant layer (13).

On the outside of at least one (preferably both) of the curable resin cured product layers (11) and (12) constituting the outer layer on the A side or B side, SiOx is formed by a sputtering method.
It is preferable to form the (1.2 <x <2) layers (11 ′) and (12 ′). The thickness of the SiOx layers (11 ') and (12'), which are optional layers, is
It is desirable that the thickness is 20 to 1000 angstroms, particularly 30 to 300 angstroms. When the thickness is too thin, the effect of providing the layer is poor, while when it is too thick, coloring or cracking tends to occur.

X in the SiOx layers (11 ') and (12') is
1.2 <x <2, preferably 1.3 ≦ x ≦ 1.9. Si
The Ox layers (11 ') and (12') have excellent resistance to acids and alkalis, have good moisture resistance, and have air resistance, and the SiOx layer (11 ') on the A side is the same as that used when ITO was formed. Since it also serves as an undercoat layer, provision of these layers provides higher quality. If both the SiOx layers (11 ') and (12') are provided, the prevention of curling of the plastics substrate can be completed completely. Therefore, it is particularly recommended to install both layers.

On the inner side sandwiched between both outer layers, there is a gas permeable layer.
In addition to (13), base film (14), curable resin cured product layer (1
5), or other layers may be present. Both outer layers are formed by the curable resin cured product layers (11) and (12) because of the rigidity, surface hardness, moisture resistance, solvent resistance, heat resistance, alignment film formability, and liquid crystal resistance required for electrode substrates, etc. This is for imparting properties such as sex. The gas permeable layer (13) is provided on the inner side in order to prevent deterioration of the liquid crystal over time and deterioration of display quality reliability.

Here, the curable resin cured product layers (11), (12), (1
5) Examples of the resin liquid for forming include an active energy ray-curable resin liquid composed of an ultraviolet ray-curable resin liquid or an electron beam-curable resin liquid. As the former UV curable resin,
A resin composition in which a prepolymer or / and a monomer having photopolymerizability is blended with other monofunctional or polyfunctional monomers, various polymers, a photopolymerization initiator, and a sensitizer as needed is used. Examples of the photopolymerizable prepolymer include ester acrylate-based, ester urethane acrylate-based, epoxy acrylate-based, and silicone acrylate-based, and the photopolymerizable monomer includes
Examples thereof include monofunctional acrylate, bifunctional acrylate, and trifunctional or higher functional acrylate. Although the latter electron beam curable resin liquid having the same composition is used, it is not necessary to add a photopolymerization initiator or a sensitizer.

As the resin liquid for forming the cured resin layer (11), (12), (15), a thermosetting resin liquid such as a phenoxy ether type crosslinkable polymer or a polyamideimide type A resin liquid such as a resin, a polyimide resin, or an epoxy resin can also be used. As the curable resin cured product layers (11), (12), (15), those obtained by taking internal crosslinking means (compounding a crosslinking agent) or external crosslinking means (irradiation with active energy rays) to amorphous polyolefin are also used. be able to.

The resin liquid for forming the curable resin cured product layers (11), (12), and (15) contains the organic gas-permeable layer (13a) of the gas-permeable layer (13) described below. A polyisocyanate compound or the like can be appropriately added to improve the adhesion.

Examples of the air permeation resistant layer (13) include an organic air permeation resistant layer (13a) and an inorganic air permeation resistant layer (13b).
Use the organic air-permeable layer (13a) alone or install the organic air-permeable layer (13a) together with the inorganic air-permeable layer (13b) (especially so that they are adjacent to each other) It is preferable.

The resin liquid for forming the organic air permeation-resistant layer (13a) is composed of a vinyl alcohol polymer, for example, polyvinyl alcohol or a copolymer modified product thereof.
Grafts / polymer alloys and ethylene content of 15-
A 50 mol% ethylene-vinyl alcohol copolymer or the like, or a mixture thereof with a crosslinking agent is preferably used. Of these, a resin liquid composed of a composition of a graft copolymer of polyvinyl alcohol and a crosslinking agent is particularly suitable. The thickness of the organic air permeation resistant layer (13a) can be set arbitrarily, but 2 to 100 μm per layer, especially 5
Often about 60 μm. If it exceeds the allowable range and becomes extremely thin, the desired air-proof property cannot be obtained, while if it becomes extremely thick, the moisture resistance and heat resistance become negative.

As the inorganic air-permeable layer (13b), SiO ₂ ,
SiOx, MgO, Al ₂ O ₃ , InO ₂ , SnO ₂ , ZnO and these 2
Layers of three, three or more mixtures can be mentioned. The thickness of the inorganic air permeation resistant layer (13b) is about 20 to 2000 angstroms, preferably about 40 to 1000 angstroms. The inorganic air-permeable layer (13b) is
Depending on its type, acid and alkali resistance may be insufficient, but since it is located inside the plastics substrate (1), it does not cause any problems.

Examples of the base film (14) include a polycarbonate film, a polysulfone film, a polyethersulfone film and a polyarylate film. The lamination of the base film (14) and other layers is often performed via an anchor coat layer.

Further, in the present invention, the surface of the curable resin cured product layer (11) on the A side is formed smooth, and the surface of the curable resin cured product layer (12) on the B side is made fine. It is formed on a round uneven surface.

Curable resin cured material layer (11) which is the layer on the A side
In order to form a smooth surface, a method is preferably adopted in which the resin liquid forming the layer is cured while being in contact with the smooth surface of the template film (M1) having a smooth surface. . For example, a smooth surface can be obtained by casting the resin liquid on the smooth surface of the template film (M1) having a smooth surface and then curing it. In addition, a mold film (M1) is placed on each of a pair of rolls arranged in parallel with a slight gap.
And other film layers are supplied, and the resin liquid is discharged toward the gap between the rolls, and both rolls are rotated in the direction in which the resin liquid is sandwiched so that the resin liquid is sandwiched. The sandwiched state If the resin liquid is cured by irradiating active energy rays or heating means, a mold film (M1)
The surface of the cured product layer on the side in contact with can be made smooth.

And thus, the curable resin cured product layer (11)
If the surface of the SiOx layer (11 ') is smoothed, the surface of the SiOx layer (11') is also smoothed even when the SiOx layer (11 ') is formed thereon.

Curable resin cured product layer (11) which is the layer on the A side
(Or the SiOx layer (11 ') formed thereon) has a smoothness of ± 0.2 μm or less, preferably ± 0.1 μm or less as measured by a non-contact surface roughness meter using light interference. Is desirable. Therefore, a template film (M1) having a smooth surface with a surface roughness of ± 0.2 μm or less, preferably ± 0.1 μm or less, and further ± 0.01 μm or less is used.

In order to form the surface of the curable resin cured product layer (12) on the side B into a fine and round uneven surface, it is preferable that the resin liquid for forming the layer is made into a fine and round uneven surface. A method is adopted in which the mold film (M2) is cured while being in contact with the uneven surface. For example, the mold film (M2) and other film layers are supplied to each of a pair of rolls arranged in parallel with a slight gap, and the resin liquid is discharged toward the gap between the rolls and both rolls are Rotate in the biting direction so that the resin liquid is sandwiched,
If the resin liquid is cured by irradiating with active energy rays or heating means in such a sandwiched state, the surface of the cured product layer on the side in contact with the mold film (M2) is a fine and round uneven surface. Can be In addition to the above method, a method of undergoing a process of curing the resin liquid forming the curable resin cured product layer (12) in a state of contacting with the uneven surface of the mold film (M2) having a fine and round uneven surface is also adopted. can do.

And thus, the curable resin cured product layer (12)
If the surface of is made into a fine and round uneven surface, S on it
Even when the iOx layer (12 ') is formed, its SiO
The surface of the x layer (12 ') also becomes a fine and round uneven surface.

The fine, round uneven surface of the curable resin cured product layer (12) has an average surface roughness Ra of 0.
05 to 0.3 μm, preferably 0.05 to 0.25 μm, and a glossiness of 30 to 12 at an incident angle of 60 ° and a light receiving angle of 60 °.
It is preferably 0, preferably 40 to 100. When the average surface roughness Ra is too small, the slipperiness is insufficient, which hinders the running property in the winding process, the ITO treatment or the liquid crystal display panel assembling process. When the average surface roughness Ra is too large, the haze becomes large and the transparency is increased. Is reduced. When the glossiness is too low, haze becomes large and the light transmission is lowered, and when it is too high, the slipperiness is insufficient and the running performance is hindered. The maximum roughness Rmax by the stylus method is 0.3-
It is desirable that the thickness is 5 μm, preferably 0.5 to 3 μm.

The mold film (M2) having a fine and round uneven surface is produced by, for example, internally adding fine particles during the production of the film. The fine and round uneven surface is a rounded rough surface, unlike a non-round rough surface such as a matte surface by sandblasting.
As the template film (M2) for this purpose, one having an uneven surface on which the above-mentioned fine and round uneven surface can be transferred and formed on the surface of the curable resin cured product layer (12) is used. That is, the fine, round uneven surface of the curable resin cured product layer (12) has an average surface roughness Ra of 0.05 to 0.05 by the stylus method.
0.3 μm, 30 ° to 120 ° in incident angle-60 ° to 60 ° in receiving angle, and 0.3 to 5 μ in maximum roughness Rmax.
Since it is m 2, a film having an uneven surface equal to or smaller than these is used as the mold film (M2). In addition, since UV irradiation is often performed through this template film (M2), the template film (M2) has a wavelength of 365 nm.
Has a light transmittance of 1% or more (preferably 3).
% Or more), and haze is preferably 90% or less (preferably 85% or less). For reference, the matted surface of the matted film by sandblast has a glossiness of, for example, 20%.

As materials for the above-mentioned mold films (M1) and (M2), biaxially stretched polyester film, biaxially stretched polypropylene film and the like are preferably used. The polyester in the biaxially stretched polyester film, polyethylene terephthalate, polybutylene terephthalate,
For example, polyethylene naphthalate.

The plastics substrate of the present invention is particularly useful as an electrode substrate for a normal liquid crystal display panel, and also as a polymer liquid crystal display substrate, an EL substrate, an ECD substrate, an IC card, and a substrate for other optical applications. Can be used.

When a liquid crystal display panel is manufactured, a transparent electrode (2) such as ITO is formed on the surface A side of the above plastics substrate (1) through an undercoat of a SiOx layer (11 '). A liquid crystal cell (3) is produced by a conventional method using the same, and further, a polarizing plate (4) or a polarizing plate (4) is provided on the B side of the plastic substrate (1) constituting the liquid crystal cell (3) via an adhesive layer (ad). Attach the phase plate (5). Although the B side is uneven, it is filled with the adhesive layer (ad), so if the refractive index of the adhesive layer (ad) is taken into consideration, the scattering of light at the interface between the B side and the adhesive layer (ad) will occur. Rarely occurs. The curable resin cured product layer (12) that constitutes the outer layer on the B side of the plastics substrate (1) is often a layer of an acrylic-based UV curable resin, and the adhesive layer (ad) is also an acrylic type. Since it is usual to use an adhesive, it is easy to match the refractive indexes of both layers.

<Function> In the plastics substrate of the present invention, since the A surface is formed as a smooth surface, an undercoat and then a transparent electrode can be formed on the smooth surface, and the B surface is Since it is formed into a fine and round uneven surface, it has a proper slipperiness and can be smoothly handled by a roll-to-roll method without covering the B side with a masking film. Therefore, complicated peeling-recoating operations such as the conventional masking film sticking method, problems of wrinkling, problems of entering air, problems of stickiness during heating, etc. are basically solved, and liquid crystal display panel manufacturing Issues on the spot are resolved.

[0036]

The present invention will be further described with reference to the following examples. Hereinafter, "parts" refers to parts by weight.

Example 1 FIG. 1 is a sectional view schematically showing an example of the plastic substrate of the present invention. FIG. 3 is a sectional view schematically showing an example of a liquid crystal display panel manufactured by using the plastic substrate.

Thickness 1 as an example of the support film (S)
On a normal transparent polyester film (biaxially stretched polyethylene terephthalate film) of 00 μm, a methylol melamine-based cross-linking agent (Sumitomo Chemical Co., Ltd.) Company-made "Sumitec M-3") at a weight ratio of solids of 100: 1
A resin liquid having a composition of 0 was cast, and the resin liquid was dried by passing through a dryer set so that the temperature gradually increased from 60 ° C to 110 ° C, and the organic permeation resistance of 30 μm was applied. A vapor layer (13a) was formed.

Then, a phenoxy ether resin (manufactured by Tohto Kasei Co., Ltd.) 6 was formed on the organic gas-proof layer (13a).
0 parts, 40 parts of methyl ethyl ketone, 20 parts of cellosolve acetate, 75 parts by weight solution of an adduct of tolylene diisocyanate and trimethylolpropane (“Coronate L” manufactured by Nippon Polyurethane Industry Co., Ltd.) The combined resin liquid is cast and the temperature is 8
It was dried by passing it through a drier set to be increased stepwise from 0 to 120 ° C., and further heat-treated at 145 ° C. for 20 minutes to form a curable resin cured product layer (15) having a thickness of 30 μm. . As a result, a laminated film having a layer structure of (S) / (13a) / (15) was obtained.

The laminated film obtained above was supplied to each of a pair of rolls arranged in parallel with a slight gap so that the curable resin cured product layer (15) side was the upper surface,
While rotating both rolls in a direction to bite each other when viewed from above, a non-solvent type epoxy acrylate-based UV-curable resin liquid (manufactured by Asahi Denka Co., Ltd.) is discharged between the rolls, and the resin liquid is sanded. Output is 120 W / cm, 1 lamp, lamp distance is 15 when sandwiched in a witch shape
Ultraviolet irradiation was carried out under the conditions of 0 mm and an integrated light quantity of 1000 mJ / cm ² to cure the above resin liquid to form an active energy ray curable resin cured product layer (15 ′) having a thickness of 15 μm. As a result, a laminated film having a layer structure of (S) / (13a) / (15) / (15 ') / (15) / (13a) / (S) was obtained.

Next, after removing the support films (S) and (S) from the laminated film, the support films (S) and (S) were supplied to one of a pair of rolls arranged in parallel with a slight gap therebetween, and the other. The roll has a thickness of 100 μm and the surface roughness is 0.0 on average.
06μm, 0.04μm maximum (less than ± 0.1μm as measured by non-contact surface roughness meter using light interference) Corona discharge smooth mold film made of untreated biaxially stretched polyethylene terephthalate film ( M1) is supplied and both rolls are rotated in a direction in which they bite each other when viewed from above, while discharging the same non-solvent type UV curable resin liquid as described above between the rolls, and the resin liquid is sandwiched. The resin solution was cured by irradiating it with ultraviolet rays under the same conditions as described above while sandwiched between the layers to form a curable resin cured product layer (11) having a thickness of 12 μm. This makes (M1) /
A laminated film having a layer structure of (11) / (13a) / (15) / (15 ') / (15) / (13a) was obtained.

A mold film (M2) having fine and round uneven surface formed by internally adding fine particles was prepared, and this mold film (M2) and the laminated film obtained above were used in the same manner as above. By carrying out the operation described above, a curable resin cured product layer (12) having a thickness of 12 μm was formed. This makes (M1) /
Since a laminated film having a layer structure of (11) / (13a) / (15) / (15 ') / (15) / (13a) / (12) / (M2) was obtained, a mold film
(M1) and (M2) were peeled and removed to obtain the intended plastics substrate (1).

The mold film (M2) used was a kneading type polyester "Ester E3000" manufactured by Toyobo Co., Ltd. and had the following properties. -Surface roughness (measured with a stylus method surface roughness meter "Shafcon 304B" manufactured by Tokyo Seimitsu Co., Ltd.): average surface roughness Ra 0.
105 μm, maximum roughness Rmax 1.557 μm ・ Light transmittance (Spectrophotometer "Ub manufactured by JASCO Corporation"
Measured by "est-55 type", transmittance for ultraviolet ray of 365 nm): 20.2% ・ Haze ("NDH-300" manufactured by Nippon Denshoku Industries Co., Ltd.)
Measured with "A"): 52.3% Gloss ("Gloss Checker I" manufactured by Horiba Ltd.)
G-310 ", glossiness at incident angle 60 ° -light receiving angle 60 °): 94

This plastics substrate (1) had properties close to those of glass in terms of rigidity, heat resistance and optical isotropy.
The mechanical strength, high hardness, moisture resistance, chemical resistance, and oxygen barrier property were also good.

Side A of the plastics substrate (1) ((1
The surface on the (1) side has a smooth surface with a surface roughness of ± 0.1 μm or less, and the surface on the B side ((12) side) is a fine and round uneven surface (average surface roughness Ra). 0.152 μm, maximum roughness Rmax
It is formed with 1.48μm and glossiness of 85).
I was able to handle the roll smoothly.

A SiOx (x = 1.9) layer (1) having a thickness of 80 angstroms was formed on the A surface side of the plastic substrate (1).
1 ') undercoat then ITO sputtered transparent electrode with a thickness of 450 Å
A liquid crystal cell (3) is formed by a conventional method using the one formed with (2).
Was produced.

Then, a polarizing plate (4) and a phase plate (5) are attached to the B side of one of the plastics substrates (1) constituting the liquid crystal cell (3) via an adhesive layer (ad). Then, the polarizing plate (4) was adhered to the B-side of the other plastics substrate (1) via the adhesive layer (ad). Upon sticking, a pressure bonding method under pressure in an autoclave was adopted according to a conventional method. The B side of each plastics substrate (1) is uneven, but since it is filled with the adhesive layer (ad), it is necessary to pay a little attention to the refractive index of the adhesive layer (ad). Light scattering at the interface between the adhesive layer and the adhesive layer (ad) hardly occurred.

Example 2 FIG. 2 is a sectional view schematically showing another example of the plastic substrate of the present invention. However, the anchor coat layer is not shown.

Thickness 10 as an example of the base film (14)
An anchor coat layer with a thickness of 1 μm or less was formed on one side of a 0 μm polycarbonate film with an aqueous anchor coating agent, and then an organic air permeation resistant layer (13a) with a thickness of 12 μm was formed in the same manner as in Example 1. Similarly, an anchor coat layer having a thickness of 1 μm or less and then an organic air permeation resistant layer (13a) having a thickness of 12 μm were formed on the other surface of the substrate film (14) in the same manner. As a result, a laminated film having a layer structure of (13a) / (14) / (13a) was obtained.

The above laminated film and the same mold film (M1) as in Example 1 were supplied to each of a pair of rolls arranged in parallel with a slight gap, and a special non-solvent type acrylate was placed between the rolls. System UV curable resin liquid (manufactured by Japan Synthetic Rubber Co., Ltd.) is discharged, and the resin liquid is sandwiched in a sandwich shape and output 120 W / c
m, 1 lamp, lamp distance 150 mm, total light intensity 1000 mJ / cm
UV irradiation under the conditions of ² to cure the resin liquid,
15 μm thick active energy ray-curable resin cured product layer (1
1) As a result, (M1) / (11) / (13a) / (14) / (13a)
A laminated film having the layer structure of was obtained.

Next, the laminated film thus obtained and the same mold film (M2) as in Example 1 were fed to each of a pair of rolls arranged in parallel with a slight gap therebetween, and both rolls were fed. While rotating the rolls so as to bite each other when viewed from above, the same non-solvent type UV-curable resin liquid as described above is discharged between both rolls, and the resin liquid is sandwiched in a sandwich form. Ultraviolet irradiation was performed under the same conditions to cure the resin liquid, and a curable resin cured product layer (12) having a thickness of 15 μm was formed. This makes (M1) / (1
1) / (13a) / (14) / (13a) / (12) / (M2) Since a laminated film having a layer structure was obtained, the mold film (M1), (M2) was peeled off, A desired plastic substrate was obtained.

The surface of the plastics substrate thus obtained on the A side ((11) side) has a smooth surface with a surface roughness of ± 0.1 μm or less, and the B side ((12 ) Side) is formed into a fine and round uneven surface (average surface roughness Ra 0.152 μm, maximum roughness Rmax 1.48 μm, glossiness 85), and without attaching a masking film to the B side. ,
We were able to handle roll-to-roll smoothly.

Example 3 After the formation of the organic gas-proof layer (13a), an inorganic gas-proof layer consisting of a metal oxide layer (composite oxide layer mainly composed of SiOx) having a thickness of 180 Å was formed by sputtering from above. Example 2 was repeated except that the vapor layer (13b) was formed. As a result, (M1) / (11) / (13b) / (13a) / (14) / (13
a) / (13b) / (12) / (M2) Since a laminated film having a layer structure was obtained, the mold films (M1) and (M2) were removed by peeling,
A desired plastic substrate was obtained.

Example 4 Sputtering was performed on the layer (11) side surface of a plastics substrate having the layer structure of (11) / (13a) / (14) / (13a) / (12) obtained in Example 2. SiOx with a thickness of 80 angstroms
A (x = 1.4) layer (11 ′) was formed. Then, a SiOx (x = 1.4) layer (12 ′) having a thickness of 80 angstrom was formed on the surface on the layer (12) side by a sputtering method. As a result, a plastics substrate having a layer structure of (11 ′) / (11) / (13a) / (14) / (13a) / (12) / (12 ′) was obtained.

Example 5 (11) / (13b) / (13a) / (14) / (13a) / (13b) / (1) obtained in Example 3
On the surface of the plastic substrate having the layer structure of 2) on the layer (11) side, a 190 Å thick SiOx (x = 1.3) layer (11 ′) was formed by a sputtering method. Then, on the layer (12) side surface, a thickness of 190 is obtained by a sputtering method.
An Angstrom SiOx (x = 1.3) layer (12 ') was formed. As a result, (11 ') / (11) / (13b) / (13a) / (14) /
A plastics substrate having a layer structure of (13a) / (13b) / (12) / (12 ') was obtained.

Example 6 As an example of the support film (S), a polyester resin (“A-513E” manufactured by Takamatsu Oil & Fat Co., Ltd.) having a concentration of 20% by weight was formed on a normal transparent polyester film having a thickness of 100 μm. After coating the aqueous dispersion, it was dried to form a precoat layer (pc) having a thickness of 2 μm. Then, an organic air permeation resistant layer (13a) having a thickness of 19 μm was formed on the precoat layer (pc) in the same manner as in Example 1. As a result, a laminated film 1 having a layer structure of (S) / (pc) / (13a) was obtained.

The above laminated film 1 and the same mold film (M1) as in Example 1 were supplied to each of a pair of rolls arranged in parallel with a slight gap, and a special non-solvent type roller was placed between the rolls. Acrylate-based UV curable resin liquid (manufactured by Japan Synthetic Rubber Co., Ltd.) is discharged, and while the resin liquid is sandwiched, it is irradiated with ultraviolet rays to cure the resin liquid, and an active energy ray with a thickness of 15 μm. No curable resin cured product layer (11), support film (S)
Was peeled off. As a result, a laminated film 2 having a layer structure of (M1) / (11) / (13a) / (pc) was obtained.

The above-mentioned laminated film 1 and the mold film (M2) having a fine and round uneven surface used in Example 1 were supplied to each of a pair of rolls arranged in parallel with a slight gap. , A non-solvent type special acrylate type UV curable resin liquid (manufactured by Japan Synthetic Rubber Co., Ltd.) is discharged between the rolls, and the resin liquid is irradiated with ultraviolet rays while sandwiched in a sandwich shape. Was cured to form an active energy ray-curable resin cured product layer (12) having a thickness of 15 μm, and the support film (S) was peeled and removed.
As a result, a laminated film 3 having a layer structure of (M2) / (12) / (13a) / (pc) was obtained.

On each of a pair of rolls arranged in parallel with a slight gap, the laminated films 2 and 3 obtained above were placed.
Are supplied so that each precoat layer (pc) side is the upper surface, and while rotating both rolls in the direction to bite each other when viewed from above, a non-solvent type epoxy acrylate type ultraviolet curing resin liquid between both rolls. (Asahi Denka Kogyo Co., Ltd.) was discharged, and while the resin solution was sandwiched in a sandwich, it was irradiated with ultraviolet rays to cure the resin solution, and a cured resin layer having a thickness of 15 μm of an active energy ray was prepared. (15 ') As a result, (M1) / (11) / (13
Since a laminated film 4 having a layer structure of a) / (pc) / (15 ') / (pc) / (13a) / (12) / (M2) was obtained, the mold films (M1) on both sides were (M2) was peeled and removed to obtain the intended plastics substrate (1).

Example 7 After the formation of the organic gas-proof layer (13a), an inorganic gas-proof layer composed of a metal oxide layer (a layer of a composite oxide mainly composed of SiOx) having a thickness of 300 Å was formed by sputtering from above. Example 6 was repeated except that the vapor layer (13b) was formed. As a result, (11) / (13b) / (13a) / (pc) / (15 ') / (p
A plastics substrate having a layer structure of c) / (13a) / (13b) / (12) was obtained.

Example 8 (11) / (13b) / (13a) / (pc) / (15 ') / (pc) / (13 obtained in Example 7
A SiOx (x = 1.9) layer (11 ') having a thickness of 80 angstrom was formed on the layer (11) side surface of a plastic substrate having a) / (13b) / (12) layer structure by a sputtering method. . Then, on the surface of the layer (12) side, a SiOx (x = 1.9) layer (1
2 ') was formed. As a result, (11 ') / (11) / (13b) / (13
A plastics substrate having a layer structure of a) / (pc) / (15 ') / (pc) / (13a) / (13b) / (12) / (12') was obtained.

Example 9 (11) / (13a) / (pc) / (15 ') / (pc) / (13a) / (1 obtained in Example 6
A 90 Å thick SiOx (x = 1.8) layer (11 ') was formed on the surface of the plastic substrate having the layer structure of 2) on the layer (11) side by a sputtering method. Then, a 90 Å thick SiOx (x = 1.8) layer (12 ′) was formed on the surface on the layer (12) side by a sputtering method. As a result, (11 ') / (11) / (13a) / (pc) / (15') / (p
A plastics substrate having a layer structure of c) / (13a) / (12) / (12 ') was obtained.

[0063]

As described in the section of the operation, in the plastics substrate of the present invention, since the surface A is formed as a smooth surface, an undercoat and then a transparent electrode are formed on the smooth surface. In addition, since the B side is formed into a fine and round uneven surface, an appropriate slip property can be obtained,
Even if the B side is not covered with a masking film, it can be handled smoothly by the roll-to-roll method.
Therefore, the complicated peeling-recoating operation, the problem of wrinkling, the problem of air entrapment, the problem of stickiness during heating, etc. as in the conventional masking film sticking method are fundamentally solved, and the manufacturing site of the liquid crystal display panel is solved. The issues that are pending will be solved.

[Brief description of drawings]

FIG. 1 is a sectional view schematically showing an example of a plastic substrate of the present invention.

FIG. 2 is a sectional view schematically showing another example of the plastic substrate of the present invention.

FIG. 3 is a cross-sectional view schematically showing an example of a liquid crystal display panel manufactured using the plastic substrate of the present invention.

[Explanation of symbols]

 (M1), (M2) ... Mold film, (1) ... Plastics substrate, (11) ... Curable resin cured product layer, (11 ') ... SiOx layer, (12) ... Curable resin cured product layer, ( 13) ... Air-permeable layer, (13a) ... Organic air-permeable layer, (14) ... Base film, (15), (15 ') ... Curable resin cured material layer, (2) ... Transparent electrode, (3) ... Liquid crystal cell, (4) ... Polarizing plate, (5) ... Phase plate, (ad) ... Adhesive layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location G02F 1/1333 500 G02F 1/1333 500

Claims (6)

[Claims] 1. When the surface of the plastics substrate (1) on which the transparent electrode is formed is named A surface and the opposite surface is named B surface, the outer layer on the A surface side of the substrate (1) is cured. Type resin cured product layer (11), the outer layer on the B side is a curable resin cured product layer (12), and at least one air permeation resistant layer is provided on the inner side sandwiched between these outer layers. (13) is present, and the surface of the curable resin cured product layer (11) on the A side is smooth, and the surface of the curable resin cured product layer (12) on the B side is fine. A plastics substrate characterized by being formed on a round uneven surface. 2. Outside of at least one of the curable resin cured product layers (11), (12) constituting the outer layer on the A side or the B side,
The plastic substrate according to claim 1, wherein SiOx (1.2 <x <2) layers (11 ') and (12') are formed. 3. A fine and round uneven surface having an average surface roughness Ra by the stylus method of 0.05 to 0.3 μm and an incident angle of 60.
The plastics substrate according to claim 1, which has a surface with a glossiness of 30 to 120 at a -60 ° light receiving angle. 4. A cured resin layer (12) which is a layer on the B side.
2. The plastic substrate according to claim 1, wherein the resin liquid forming the layer is formed through a process of curing while being in contact with the uneven surface of the mold film (M2) having a fine and round uneven surface. . 5. A curable resin cured product layer (11) which is a layer on the A side.
2. The plastics substrate according to claim 1, wherein the resin liquid forming the layer is formed through a process of curing while the resin liquid forming the layer is in contact with the smooth surface of the mold film (M1) having a smooth surface. 6. A cured resin layer (11) which is a layer on the A side.
2. The plastic substrate according to claim 1, wherein the smoothness of the surface is ± 0.2 μm or less as measured by a non-contact type surface roughness meter utilizing light interference.