KR20090045105A - Curable resin composition for hard coat layer and hard coat film - Google Patents

Abstract

assignment

A hard coat film provided with the desired irregularities on the surface of the hard coat layer without impairing transparency and scratch resistance.

Resolution

(1) Reactive inorganic fine particles A having an average primary particle diameter of 5 nm or more and 80 nm or less and covering at least a part of the surface with an organic component and having a reactive functional group a introduced by the organic component on the surface, (2) Hydrophilic fine particles B having an average primary particle diameter of 100 nm or more and 300 nm or less, and (3) a cured reactive matrix containing a binder component C having a reactive functional group c having a crosslinking reactivity with the reactive functional group a of the reactive inorganic fine particles A; Content of the said hydrophilic microparticles | fine-particles B is 0.1-5.0 weight% of curable resin composition for hard coat layers with respect to a total solid, apply | coat, dry, and harden on a transparent base film, Preferably it is larger than 3 nm on the hard-coat layer surface The hard-coat film which has convex parts of 50 nm or less in height, and provided the unevenness | corrugation of 50 nm-5 micrometers of space | intervals between convex parts.

Description

Curable resin composition for hard coat layer and hard coat film {CURABLE RESIN COMPOSITION FOR HARD COAT LAYER AND HARD COAT FILM}

The present invention relates to a hard coat film having a curable resin composition for forming a hard coat layer of a hard coat film used for the purpose of protecting the surface of a display or the like, and a hard coat layer using the curable resin composition. .

The image display surface in image display apparatuses, such as a liquid crystal display, a CRT display, a projection display, a plasma display, an electroluminescent display, is required to provide scratch resistance so that a scratch may not arise at the time of handling. . On the other hand, the image of an image display apparatus is used by using the hard-coat film which formed the hard-coat (HC) layer in the base film, and the hard-coat film (optical laminated body) which gave optical functions, such as antireflection property and anti-glare property, further. It is common to improve the scratch resistance of a display surface.

And when there are many unevenness | corrugations on the surface of a hard-coat layer, when a hard thing comes into contact with something hard, it will be caught in a convex part, and an excessive force is applied to this convex part, and there exists a possibility of causing a fine damage. Therefore, in order to improve the scratch resistance of the surface of the hard coat layer, it is necessary to smooth the surface of the hard coat layer.

In particular, when the surface of the hydrophobized surface of the inorganic inorganic particles having a particle size of 80 nm or less and the cured product of the binder component are used as the hard coat layer, the reactive inorganic fine particles are uniformly dispersed in the binder component and the surface is smoothed. A hard coat film of is obtained.

However, when the hard coat film having a high surface smoothness is continuously wound in a continuous band form to form a long roll, the surface on the hard coat layer side of the hard coat film and the hard surface thereof are the same as when the mirror surfaces are pressed closely. The surface on the base film side of the coat film overlaps and adheres. The strength at the time of attachment differs in the outer edge part and center part of a roll.

For this reason, in the manufacturing process of the product using a hard-coat film, it is difficult to control the feed rate of the hard-coat film, and when the hard-coat film surface peels off mutually attached, the hard-coat film breaks off. There is a problem.

As means for preventing the close contact between such mirror surfaces, it is conceivable to form a minute projection at one or both sides of the mirror surfaces to be joined at an appropriate distribution density such that the smoothness of the mirror surfaces is not impaired.

Patent Document 1 discloses that flaky and irregular flaky inorganic fine particles are contained in the curable resin composition for a hard coat layer, and the hard coat layer is formed using the resin composition, whereby the surface of the hard coat layer is inorganic fine particles. It is thought that the micro projections can be formed because they are partially pushed up.

However, when the curable resin composition for hard coat layer contains inorganic fine particles of flaky and irregular flakes, transparency of the hard coat layer made of the resin composition is lowered due to increased internal scattering in the layer.

In patent document 2, after application | coating of the composition which consists of a 1st component which consists of resin, and the 2nd component which consists of monomers or an oligomer, resin of a 1st phase phase-separates and precipitates, and forms the anti-blocking curability which forms fine unevenness | corrugation. Although a resin composition is described, according to this composition, since the difference of SP value of both components is used, the material which can be used is restrict | limited and it is difficult to express sufficient hard coat property in many cases, and also the drying temperature conditions in film forming etc. It is easy to be influenced, and it is hard to obtain a stable effect.

In addition, the addition of the compound which has anti-sticking property of patent documents 3-5 has high surface flatness, and can hardly exhibit the effect under strong pressure.

Moreover, when the crosslinked polymer particle which has polysiloxane and a fluorine-containing polymer is used for the particle | grain surface described in patent document 6 and patent document 7, in a hydrophobic binder component, unevenness is hard to be formed in the surface, and it does not exert sufficient effect.

[Patent Document 1] Japanese Unexamined Patent Publication No. 2004-42653

[Patent Document 2] Japanese Unexamined Patent Publication No. 2007-182519

[Patent Document 3] Japanese Patent Publication No. 2658200

[Patent Document 4] Japanese Patent Application Laid-Open No. 6-100629

[Patent Document 5] Japanese Unexamined Patent Publication No. Hei 10-7866

[Patent Document 6] Japanese Patent Application Laid-Open No. 7-207029

[Patent Document 7] Japanese Patent Application Laid-Open No. 7-225490

The present invention provides a hard coat film using a curable resin composition for a hard coat layer capable of forming a hard coat layer having a desired concavo-convex shape on the surface thereof without impairing transparency and scratch resistance, and a curable resin composition for the hard coat layer. The purpose is to.

As a result of earnest research, the inventors have found that the curable resin composition for a hard coat layer contains reactive inorganic fine particles A having a specific average primary particle diameter and hydrophilic fine particles B having a specific average primary particle diameter, thereby maintaining transparency and scratch resistance. The inventors have obtained the knowledge that a hard coat film provided with the desired irregularities on the surface of the hard coat layer can be obtained, thereby completing the present invention.

That is, the present invention,

(1) Reactive inorganic fine particles A having an average primary particle diameter of 5 nm or more and 80 nm or less, covering at least a part of the surface with an organic component and having a reactive functional group a introduced by the organic component on the surface;

(2) hydrophilic fine particles B having an average primary particle diameter of 100 nm or more and 300 nm or less,

(3) a cured reactive matrix containing a binder component C having a reactive functional group c having a crosslinking reactivity with the reactive functional group a of the reactive inorganic fine particles A

It contains at least, and content of the said hydrophilic microparticles | fine-particles B provides curable resin composition for hard coat layers which is 0.1-5.0 weight% with respect to a total solid.

Moreover, in the optical laminated body which laminated | stacked at least 1 layer of hardened | cured material of the said hard-coat layer curable resin composition, the hardness of the whole resin layer laminated | stacked on the transparent base material in the case of a single | mono layer or a multilayer was measured by the indentation load 10mN. In this case, the indentation depth is 1.3 μm or less. As the optical laminate has such hardness, when the concave-convex shape is present, the adhesion of the mirror surfaces can be effectively prevented.

According to the present invention, the curable resin composition for hard coat layer contains the reactive inorganic fine particles A in the above range so that the average primary particle size does not impair the transparency of the hydrophilic fine particles B in the above range. The hard coat film which provided the desired uneven | corrugated shape to the hard-coat layer surface in small quantity of can be obtained. Moreover, since the reactive functional group a of the reactive inorganic fine particles A contained in the said hardening reactive matrix and the reactive functional group c of the curable binder component C form a crosslinked bond, the hard coat film which has high hard coat property can be obtained.

In the curable resin composition for hard coat layers which concerns on this invention, it is preferable that the said reactive inorganic fine particles A are reactive silica fine particles.

Moreover, the surface of the said reactive inorganic fine particle A is hydrophobic, ie, wettability with respect to a hydrophobic solvent, improves affinity with the binder component C mentioned later, and can disperse | distribute uniformly in a binder.

On the other hand, the hydrophilic fine particles B according to the present invention are hydrophilic on the surface and are mixed with the hydrophobic binder in the process of forming the coating film, but tend to separate from the hydrophobic environment, so that the hydrophilic fine particles B are bleed out to the vicinity of the surface of the film to form irregularities on the surface. It is preferable because it can be formed. In the present invention, the hydrophilicity is determined to be wet to alcohol. This means that there is no hydrophilicity enough to have water wettability, and enough hydrophilicity to coexist in a hydrophobic environment.

In the curable resin composition for hard coat layers which concerns on this invention, it is preferable that the reactive functional group a of the said reactive inorganic fine particles A and the reactive functional group c of the said binder component C are a polymerizable unsaturated group.

In the curable resin composition for hard coat layers which concerns on this invention, it is preferable that the said binder component C is a compound which has 3 or more of said reactive functional groups c.

It is preferable that binder C has hydrophobicity, ie, solubility in a hydrophobic solvent at the same time.

Moreover, in the hard coat film which concerns on this invention, transparency and abrasion resistance of this hard coat layer are provided on a transparent base film by providing the hard coat layer which consists of hardened | cured material of the curable resin composition for hard coat layers which concerns on this invention. The hard coat film which provided the desired uneven | corrugated shape to the hard-coat layer surface can be provided, without damaging.

In the hard coat film which concerns on this invention, the hydrophilic microparticles | fine-particles B in the said hard-coat layer have convex parts larger than 3 nm and 50 nm or less on the surface of the said hard coat layer, and the space | interval of convex parts is 50 nm-5 micrometers. Provided are hard coat films having irregularities.

According to this invention, since the desired uneven | corrugated shape is formed in the said hard-coat layer surface, when the said hard-coat film is wound continuously in a continuous strip form and it is set as a long roll, the hard-coat layer side of the hard-coat film Adhesion of the surface of and the surface of the base film side of the hard coat film can be prevented.

In the hard coat film which concerns on this invention, it is preferable that the film thickness of the said hard coat layer is 1 micrometer or more and 50 micrometers or less.

The hard coat film which concerns on this invention is suitable for using it in the form of the elongate film which is wound up continuously in a continuous strip | belt-shaped state.

According to the present invention, the curable resin composition for hard coat layer contains the reactive inorganic fine particles A in the above range so that the average primary particle size does not impair the transparency of the hydrophilic fine particles B in the above range. The hard coat film which provided the desired uneven | corrugated shape to the hard-coat layer surface in small quantity of can be obtained. Moreover, since the reactive functional group a of the reactive inorganic fine particles A contained in the said hardening reactive matrix and the reactive functional group c of the curable binder component C form a crosslinked bond, the hard coat film which has high hard coat property can be obtained.

Moreover, according to the hard coat film which concerns on this invention, when this hard coat film is wound continuously in a continuous strip form, and it is set as a long roll, the surface of the hard coat layer side of the hard coat film, and the hard coat film Adhesion of the surface on the base film side can be prevented.

The present invention relates to a curable resin composition for a hard coat layer and a hard coat film using the curable resin composition. Hereinafter, curable resin composition for hard-coat layers and a hard-coat film are demonstrated in order.

I. Curable Resin Composition for Hard Coat Layer

First, the curable resin composition for hard coat layers of this invention is demonstrated.

Curable resin composition for hard-coat layers of this invention,

(1) Reactive inorganic fine particles A having an average primary particle diameter of 5 nm or more and 80 nm or less, covering at least a part of the surface with an organic component and having a reactive functional group a introduced by the organic component on the surface;

(2) hydrophilic fine particles B having an average primary particle diameter of 100 nm or more and 300 nm or less,

(3) A curable reactive matrix containing a binder component C having a reactive functional group c having a crosslinking reactivity with the reactive functional group a of the reactive inorganic fine particles A

It contains at least, and content of the said hydrophilic microparticles | fine-particles B is 0.1-5.0 weight% with respect to total solid, It is characterized by the above-mentioned.

According to the present invention, the curable resin composition for hard coat layer contains the reactive inorganic fine particles A in the above range so that the average primary particle size does not impair the transparency of the hydrophilic fine particles B in the above range. The hard coat film which provided the desired uneven | corrugated shape to the hard-coat layer surface in small quantity of can be obtained. In addition, since the reactive functional group a of the reactive inorganic fine particles A contained in the cured reactive matrix and the reactive functional group c of the curable binder component C form a crosslink, a hard coat film having high hard coatability can be obtained.

EMBODIMENT OF THE INVENTION Below, this invention is demonstrated in detail.

The reactive inorganic fine particles A and the hydrophilic fine particles B tend to be separated by the hydrophobic group of the reactive inorganic fine particles A and the hydrophilic groups of the hydrophilic fine particles B. Moreover, although it is not bound by a specific theory, it is possible to analyze the effect of this invention as follows by making the average primary particle diameter of the said reactive inorganic fine particle A into the said range.

(i) Even in the presence of the hydrophilic fine particles B, the reactive inorganic fine particles A can be uniformly dispersed in the hard coat layer, thereby making it possible to express hard performance throughout the layer while maintaining smooth and high transparency.

(ii) Since the reactive inorganic fine particles A are dispersed throughout the hard coat layer, it can be assumed that the hydrophilic fine particles B move in the hard coat layer so as to take an optimum form in order to coexist with the fine particles A. Since the hydrophilic fine particles B have a property of repelling with the fine particles A, they are easily present in a single fine particle form (individual) or as two or more aggregates, and are generally present in a balanced manner. For example, the SEM photograph shown in FIG. 1 has shown the presence of the latter aggregate. When the individual or two aggregates of the hydrophilic fine particles B are present in the vicinity of the interface on the side opposite to the transparent base film side of the hard coat layer, a repulsive action acts greatly between the reactive inorganic fine particles A, and the hydrophilic fine particles B are very interfaces. It is extruded to a part (within 300 nm from an interface with air). However, although the hydrophilic fine particles B itself are extruded from the hard coat layer and do not come into contact with air, the reactive inorganic fine particles A are always mixed with the resin component or the resin component which forms the hard coat layer. It is coated on the film of the component. As a result, the hard coat layer can maintain good scratch resistance.

(iii) After the saponification treatment, when the hydrophilic fine particles B are not covered with a film such as a resin, the fine particles are eroded by the alkali and are eliminated, so that the adhesion between the mirror surfaces cannot be prevented. If it is coated as in the present invention, such defects do not occur and are satisfactory.

Since the individual or two aggregates of the hydrophilic fine particles B are suitably present at the interface portion by the above mechanism, when the average primary particle diameter of the reactive inorganic fine particles A is set within the above range, the surface of the hard coat layer is Content of the hydrophilic microparticles | fine-particles B which can form an uneven | corrugated shape can be suppressed in 0.1 to 5.0 weight% with respect to a total solid in small quantity. On the other hand, when a large amount of said hydrophilic microparticles | fine-particles B are contained in curable resin composition for hard-coat layers, transparency will fall by the hard-coat layer which consists of this resin composition by the internal scattering increase in a layer.

Moreover, according to this invention, a desired uneven | corrugated shape can be formed in the hard-coat layer surface by making the average primary particle diameter of the said hydrophilic fine particle B into the said range. On the other hand, when the average primary particle diameter of the hydrophilic fine particles B exceeds the above range, the surface shape of the hard coat layer becomes rough, and the transparency of the hard coat layer is damaged due to the rise of the surface haze, and The concavo-convex shape of the surface of the hard coat layer becomes large, and the smoothness of the surface of the hard coat layer is damaged, and the external force tends to be affected.

Therefore, according to the curable resin composition for hard coat layers which concerns on this invention, the hard cord layer is contained in the resin composition by containing the reactive inorganic fine particle A which has a specific mean primary particle diameter, and the hydrophilic fine particle B which has a specific average primary particle diameter. Both microparticles | fine-particles can be existed in a balanced manner, and the hard coat film which provided the desired uneven | corrugated shape to the hard-coat layer surface can be obtained, without compromising transparency and abrasion resistance.

Moreover, according to this invention, in the optical laminated body which laminated | stacked at least 1 layer of hardened | cured material of the said curable resin composition for hard-coat layers, the hardness of the whole resin layer laminated | stacked on the transparent base material in the case of a single layer, a multilayer, or a press-fit load is When measured with 10 mN, it is represented by the indentation depth of 1.3 micrometers or less. The presence of the concave-convex shape in such a hardness range makes it possible to effectively prevent adhesion of mirror surfaces of the optical laminate. When hardness is more than the said hardness range, even if an uneven | corrugated shape exists, an unevenness | corrugation falls in the flexible hard-coat surface, and it may not be able to prevent adhesion with a transparent base material as thought. Since the hardness of a resin layer is so preferable that it is high, there is no minimum in particular in a press-in depth.

Hereinafter, each structural component of curable resin composition for hard-coat layers of this invention is demonstrated in detail in order.

In addition, in this specification, (meth) acryloyl shows acryloyl and methacryloyl, and (meth) acrylate shows an acrylate and methacrylate. In addition, the "light" in this specification includes not only the electromagnetic wave of the wavelength of a visible and an invisible region, but particle beams, such as an electron beam, and the radiation or ionizing radiation which generically refers to an electromagnetic wave and a particle beam.

Reactive functional group a and reactive functional group c in this specification contain a photocurable functional group and / or a thermosetting functional group. A photocurable functional group means a functional group which can harden a coating film by advancing a polymerization reaction, a crosslinking reaction, etc. by light irradiation, For example, polymerization reactions, such as photoradical polymerization, photocationic polymerization, and photoanion polymerization, Or the reaction advances by reaction types, such as addition polymerization or condensation polymerization which advance through photodimerization, is mentioned. In addition, the thermosetting functional group in this specification means the functional group which can harden a coating film by advancing a polymerization reaction, a crosslinking reaction, etc. between the same functional groups or another functional group by heating.

Especially as a reactive functional group a and a reactive functional group c used for this invention, a polymerizable unsaturated group is used preferably from a viewpoint of improving the hardness of a cured film, Preferably it is a photocurable unsaturated group, Especially preferably, it is an ionizing radiation curable unsaturated group. . As the specific example, ethylenically unsaturated bonds, such as a (meth) acryloyl group, a vinyl group, an allyl group, etc. are mentioned.

In the present specification, the average primary particle size means a 50% particle diameter (median diameter d ₅₀₎ when measuring the particles in the solution by dynamic light scattering method, and revealed the particle size distribution cumulative distribution. The average primary particle diameter can be measured using the Microtrac particle size analyzer manufactured by Nikkiso Corporation.

<Reactive Inorganic Particles A>

Incorporation of the inorganic fine particles into the hard coat layer generally improves the hard coat property while maintaining transparency. In addition, the hard coat property can be further improved by crosslinking the inorganic fine particles having crosslinking reactivity with the curable binder to form a crosslinked structure. The reactive inorganic fine particles A refer to inorganic fine particles having an organic component coated on at least part of the surface of the inorganic fine particles serving as a core and having a reactive functional group introduced by the organic component on the surface. The reactive inorganic fine particles A include those having two or more inorganic fine particles serving as a core per particle. Moreover, the reactive inorganic fine particle A can raise the crosslinking point in a matrix with respect to content by making particle size small.

In the present invention, for the purpose of remarkably improving the hardness so as to have sufficient scratch resistance, at least a part of the surface is coated with an organic component and contains a reactive inorganic fine particle A having a reactive functional group a introduced by the organic component on the surface. It is preferable. The reactive inorganic fine particles A may further impart a function to the hard coat layer, and may be appropriately selected and used according to the purpose.

As the inorganic fine particles, for example, metal oxide fine particles such as silica, aluminum oxide, zirconia, titania, zinc oxide, germanium oxide, indium oxide, tin oxide, indium tin oxide (ITO), antimony oxide, cerium oxide, magnesium fluoride, Metal fluoride microparticles | fine-particles, such as sodium fluoride, etc. are mentioned. Metal fine particles, metal sulfide fine particles, metal nitride fine particles and the like may be used.

Silica and aluminum oxide are preferable at the point with high hardness. Moreover, in order to make a relatively high refractive index layer, the microparticles | fine-particles whose refractive index becomes high at the time of film formation of zirconia, titania, antimony oxide, etc. can be selected suitably, and can be used. Similarly, in order to make a relatively low refractive index layer, the microparticles | fine-particles whose refractive index becomes low at the time of film formation, such as fluoride microparticles | fine-particles, such as magnesium fluoride and sodium fluoride, can be selected suitably and used. In addition, in order to provide antistatic property and electrical conductivity, indium tin oxide (ITO), tin oxide, etc. can be selected suitably, and can be used. These can be used individually by 1 type or in combination of 2 or more types.

The surface of the inorganic fine particles usually has a group which cannot exist in this form in the inorganic fine particles. Groups on these surfaces are usually relatively reactive groups. For example, in the case of a metal oxide, it has a hydroxyl group and an oxy group, in the case of a metal sulfide, thiol group and a thi group, or in the case of a nitride, an amino group, an amide group, and an imide group.

It is preferable from the viewpoint of abrasion resistance that the reactive inorganic fine particle A which concerns on this invention is a reactive silica fine particle whose inorganic fine particle which becomes a core is silica.

In addition, the reactive inorganic fine particles A according to the present invention use solid particles that do not have voids or porous structures in the particles, rather than particles having voids or porous structures in the particles such as hollow particles. It is preferable. In the hollow particles, since the particles have pores or porous structures inside them, the hardness is lower than that of the solid particles, and the hollow particles have an apparent specific gravity (mass per unit volume averaged including the hollow portion) compared to the solid particles, and thus hard coat. The hollow particles which exist in the interface on the opposite side (so-called air interface side) from the transparent base film side of the layer tend to increase. By the volume exclusion effect of the reactive inorganic fine particles A, from the viewpoint of localizing the hydrophilic fine particles B on the so-called air interface side, as the reactive inorganic fine particles A, it is preferable to use solid particles rather than hollow particles that are easily localized on the air interface side. Therefore, it is preferable that the reactive inorganic fine particles A have high hardness and use solid particles having a specific gravity larger than that of the hollow particles.

The reactive inorganic fine particle A used for this invention coat | covers an organic component in at least one part of the surface, and has the reactive functional group introduce | transduced by this organic component on the surface. Here, an organic component is a component containing carbon. Moreover, in the aspect in which the organic component is coat | covered at least one part of the surface, the compound containing organic components, such as a silane coupling agent, reacts with the hydroxyl group which exists in the surface of metal oxide microparticles | fine-particles, for example, and it is organic to a part of surface. In addition to the embodiment in which the component is bonded, for example, an embodiment in which the organic component is attached to the hydroxyl group present on the surface of the metal oxide fine particles by an interaction such as hydrogen bonding, or one or two or more inorganic fine particles in the polymer particles. Aspects and the like are included.

It is preferable that the coated organic component covers almost the whole of the particle | grain surface from the point which suppresses aggregation of inorganic microparticles, and introduce | transduces the number of reactive functional groups to the inorganic particle surface, and improves the hardness of a film | membrane. From this viewpoint, it is preferable that the said organic component which coat | covers inorganic fine particle is contained in reactive inorganic fine particle A 1.00x10 <^-3> g / m <2> or more. In the embodiment in which the organic component is attached to or bonded to the surface of the inorganic fine particles, the organic component covering the inorganic fine particles is more preferably 2.00 × 10 ⁻³ g / m 2 or more contained in the reactive inorganic fine particles A, and the reactive inorganic fine particles A It is especially preferable to contain 3.50x10 <^-3> g / m <2> or more in the inside. In an embodiment in which the inorganic particles are contained in the polymer particles, the organic component covering the inorganic fine particles is more preferably contained at least 3.50 × 10 ⁻³ g / m 2 or more in the reactive inorganic fine particles A, and is preferably 5.50 × in the reactive inorganic fine particles A. It is especially preferable to contain ^10-3 g / m <2> or more.

The proportion of the coated organic component is usually a constant value of weight loss when the dry powder is completely burned in air, and can be determined, for example, by thermogravimetric analysis from room temperature to 800 ° C in air.

In addition, the amount of organic components per unit area is calculated | required by the following method. First, the value (organic component weight / inorganic component weight) obtained by dividing the organic component weight by the inorganic component weight is measured by differential thermogravimetric analysis (DTG). Next, the volume of the entire inorganic component is calculated from the weight of the inorganic component and the specific gravity of the inorganic fine particles used. In addition, assuming that the inorganic fine particles before coating are spherical, the volume and surface area per inorganic fine particles before coating are calculated from the average particle diameter of the inorganic fine particles before coating. Next, the number of reactive inorganic fine particles A is calculated | required by dividing the volume of the whole inorganic component by the volume per inorganic fine particle before coating | coating. In addition, the organic component amount per one reactive inorganic fine particle A is calculated | required by dividing the weight of an organic component by the number of reactive inorganic fine particles A. Finally, the organic component amount per unit area can be obtained by dividing the organic component weight per reactive inorganic fine particle A by the surface area per inorganic fine particle before coating.

Although the average primary particle diameter of the reactive inorganic fine particles A is 5 nm or more and 80 nm or less from a viewpoint of improving hardness, without impairing transparency, Especially preferably, they are 30 nm or more and 70 nm or less.

In addition, the reactive inorganic fine particles A may be an aggregate, and in the case of an aggregate, not only the primary particle diameter but also the secondary particle diameter may be within the above range.

As a method of preparing the reactive inorganic fine particle A which has an organic component coat | covered at least a part of the surface, and has the reactive functional group introduce | transduced by this organic component on the surface, it is conventionally well-known by the reactive functional group a to introduce | transduce into the inorganic fine particle. The selected method may be appropriately selected and used.

In particular, in the present invention, the coated organic component can be contained in the reactive inorganic fine particles A in a range of 1.00 × 10 ⁻³ g / m 2 or more per unit area of the inorganic fine particles before coating, and the aggregation of the inorganic fine particles can be suppressed to reduce the hardness of the membrane. It is preferable to select and use any one of the following inorganic fine particles of (i), (ii), (iii) suitably from the point which improves.

(i) saturated or unsaturated carboxylic acids, acid anhydrides, acid chlorides, esters and acidamides corresponding to the carboxylic acids, amino acids, imines, nitriles, isonitriles, epoxy compounds, amines, β-dicarbonyl compounds, silanes and The inorganic fine particle which has a reactive functional group on the surface obtained by disperse | distributing an inorganic fine particle in water and / or an organic solvent as a dispersion medium in presence of 1 or more types of molecular weight 500 or less surface modification compounds chosen from the group which consists of a metal compound which has a functional group.

(ii) A monomer obtained by dispersing inorganic fine particles having a particle diameter of 5 nm or more and 80 nm or less in a hydrophobic vinyl monomer was discharged into the water through a hydrophilized porous membrane to obtain a water dispersion of monomer droplets in which inorganic fine particles were dispersed. The inorganic fine particle which has a reactive functional group on the surface obtained by superposing | polymerizing after it.

(iii) a surface obtained by combining a metal oxide fine particle with a compound containing a reactive functional group to be introduced into the inorganic fine particle before coating, a group represented by the following formula (1), and a silanol group or a group which generates a silanol group by hydrolysis; Inorganic fine particles having a reactive functional group to the.

Formula (1)

-Q ¹ -C (= Q ² ) -NH-

(In Formula (1), Q ¹ represents NH, O (oxygen atom) or S (sulfur atom), and Q ² represents O or S).)

Hereinafter, the reactive inorganic fine particles A which are preferably used in the present invention will be described in order.

(i) saturated or unsaturated carboxylic acids, acid anhydrides, acid chlorides, esters and acidamides corresponding to the carboxylic acids, amino acids, imines, nitriles, isonitriles, epoxy compounds, amines, β-dicarbonyl compounds, silanes, And inorganic fine particles having a reactive functional group on the surface, obtained by dispersing the inorganic fine particles in water and / or an organic solvent as a dispersion medium in the presence of at least one molecular weight 500 or less surface modified compound selected from the group consisting of metal compounds having functional groups. .

In the case of using the reactive inorganic fine particles A of (i), there is an advantage that the organic component content can at least improve the film strength.

The surface modification compound used for the reactive inorganic fine particles A of (i) may be a carboxyl group, an acid anhydride group, an acid chloride group, an acid amide group, an ester group, an imino group, a nitrile group, an isonitrile group, a hydroxyl group, a thiol group, an epoxy group, Groups present on the surface of the inorganic fine particles under dispersion conditions such as primary, secondary and tertiary amino groups, Si-OH groups, hydrolyzable residues of silane, or CH acid groups such as β-dicarbonyl compounds; It has a functional group which can chemically bond. The chemical bonds here preferably include covalent bonds, ionic bonds or coordinate bonds, and hydrogen bonds are also included. Coordination bonds are thought to form complexes. For example, acidic / base reactions, complex formation or esterification according to Bronsted or Lewis occur between the functionalities of the surface modification compounds and the groups on the inorganic particulate surface. The said surface modification compound used for the reactive inorganic fine particles A of said (i) can be used 1 type or in mixture of 2 or more types.

After the surface modification compound is bonded to the surface modification compound through the functional group, in addition to at least one functional group (hereinafter referred to as a first functional group) that may be typically involved in chemical bonding with a group on the surface of the inorganic fine particle, It has molecular residues that impart new properties to inorganic fine particles. Molecular residues, or portions thereof, are hydrophobic or hydrophilic, for example to stabilize, blend or activate inorganic particulates.

For example, examples of the hydrophobic molecular moiety include alkyl, aryl, alkaryl, aralkyl, or fluorine-containing alkyl groups having inactivation or repulsive action. Examples of the hydrophilic group include a hydroxy group, an alkoxy group or a polyester group.

The reactive functional group a introduced to the surface is appropriately selected according to the binder component C so that the reactive inorganic fine particles A can react with the binder component C described later. As the reactive functional group a, a polymerizable unsaturated group is preferably used, preferably a photocurable unsaturated group, and particularly preferably an ionizing radiation curable unsaturated group. As the specific example, ethylenic double bonds, such as a (meth) acryloyl group, a vinyl group, and an allyl group, etc. are mentioned.

When the reactive moiety a which can react with the binder component C is contained in the molecular moiety of the surface modification compound, the surface of the inorganic fine particle is reacted by reacting the first functional group contained in the surface modification compound with the surface of the inorganic fine particle. The reactive functional group a that can react with the binder component C can be introduced on the surface of the reactive inorganic fine particles A. For example, in addition to a 1st functional group, the surface modification compound which has a polymerizable unsaturated group is mentioned as a preferable thing.

On the other hand, a second reactive functional group is contained in the molecular moiety of the surface modification compound, and the second reactive functional group can be reacted with the binder component C on the surface of the reactive inorganic fine particles A of (i). Reactive functional group a may be introduced. For example, as a second reactive functional group, a hydrogen bond forming group (hydrogen bond forming group) capable of hydrogen bonding such as a hydroxyl group and an oxy group is introduced, and the hydrogen bond forming group of another surface-modified compound reacts with the hydrogen bond forming group introduced on the surface of the particulate. It is preferable to introduce the reactive functional group a which can react with the said binder component C by this. That is, as a surface modification compound, using together the compound which has a hydrogen bond former, and the compound which has a reactive functional group a which can react with the said binder component C, such as a polymerizable unsaturated group, and a hydrogen bond former is used together is a preferable example. Can be. Specific examples of the hydrogen bond forming group include a hydroxyl group, a carboxyl group, an epoxy group, a glycidyl group, a functional group such as an amide group, or an amide bond. Here, an amide bond includes -NHC (O)-and> NC (O)-in a coupling unit. As a hydrogen bond former used for the surface modification compound of this invention, a carboxyl group, a hydroxyl group, and an amide group are especially preferable.

The surface modification compound used for the reactive inorganic fine particles A of (i) has a molecular weight of 500 or less, more preferably 400, particularly not exceeding 200. Since it has such a low molecular weight, it is estimated that it can occupy the surface of inorganic fine particles rapidly, and can interfere with aggregation of inorganic fine particles.

The surface modification compound used for the reactive inorganic fine particles A of (i) is preferably a liquid under reaction conditions for surface modification, and is preferably soluble or at least emulsifiable in a dispersion medium. Especially, it is preferable to melt | dissolve in a dispersion medium and to distribute | distribute and exist like a molecule or molecular ion disperse | distributed in a dispersion medium.

Saturated or unsaturated carboxylic acids have from 1 to 24 carbon atoms, for example, formic acid, acetic acid, propionic acid, butyric acid, valeric acid, capric acid, acrylic acid, methacrylic acid, crotonic acid, citric acid, adipic acid , Succinic acid, glutaric acid, oxalic acid, maleic acid, fumaric acid, itaconic acid and stearic acid, and corresponding acid anhydrides, chlorides, esters and amides such as caprolactam and the like. Moreover, when unsaturated carboxylic acid is used, a polymerizable unsaturated group can be introduce | transduced.

Examples of preferred amines are those having the formula Q _3-n NH _n (n = 0, 1 or 2), in which the residues Q are independently 1 to 12, especially 1 to 6, particularly preferably 1 to 4 carbon atoms Alkyl having (eg methyl, ethyl, n-propyl, i-propyl and butyl), and aryl, alkaryl or aralkyl having 6 to 24 carbon atoms (eg phenyl, naphthyl, tolyl and Benzyl). In addition, examples of preferred amines include polyalkyleneamines, and specific examples include methylamine, dimethylamine, trimethylamine, ethylamine, aniline, N-methylaniline, diphenylamine, triphenylamine, toluidine, ethylene Diamine and diethylenetriamine.

Preferred β-dicarbonyl compounds have 4 to 12, in particular 5 to 8, carbon atoms, for example diketone (acetylacetone, etc.), 2,3-hexanedione, 3,5-heptanedione, acetoacetic acid And acetoacetic acid-C ₁ -C ₄ -alkyl esters (such as acetoacetic acid ethyl ester), diacetyl and acetonyl acetone.

Examples of amino acids include β-alanine, glycine, valine, aminocaproic acid, leucine and isoleucine.

Preferred silanes are hydrolyzable organosilanes having at least one hydrolyzable group or hydroxy group and at least one non-hydrolyzable moiety. As a hydrolyzable group here, a halogen, an alkoxy group, and an acyloxy group are mentioned, for example. As the non-hydrolyzable moiety, a non-hydrolyzable moiety having a reactive functional group a and / or not having a reactive functional group a is used. Moreover, you may use the silane which has an organic residue substituted at least in part by fluorine.

The silane to be used is not particularly limited, for example, _{CH 2 = CHSi (OOCCH 3)} 3, CH 2 = CHSiCl 3, CH 2 = CHSi (OC 2 H 5) 3, CH 2 = CHSi (OC 2 H ₄ OCH ₃ ) ₃ , CH ₂ = CH-CH ₂ -Si (OC ₂ H ₅ ) ₃ , CH ₂ = CH-CH ₂ -Si (OOCCH ₃ ) ₃ , γ-glycidyloxypropyltrimethoxysilane (GPTS), γ-glycidyloxypropyldimethylchlorosilane, 3-aminopropyltrimethoxysilane (APTS), 3-aminopropyltriethoxysilane (APTES), N- (2-aminoethyl) -3- Aminopropyltrimethoxysilane, N- [N '-(2'-aminoethyl) -2-aminoethyl] -3-aminopropyltrimethoxysilane, hydroxymethyltrimethoxysilane, 2- [methoxy ( Polyethyleneoxy) propyl] trimethoxysilane, bis- (hydroxyethyl) -3-aminopropyltriethoxysilane, N-hydroxyethyl-N-methylaminopropyltriethoxysilane, 3- (meth) acryloxy Propyltriethoxysilane, 3- (meth) acryloxypropyltrimethoxysilane, and the like. .

As a metal compound which has a functional group, the metal compound of the metal M from the 1st group III-V and / or the 2nd group II-IV of an element periodic table is mentioned. Alkoxides of zirconium and titanium, M (OR) ₄ (M = Ti, Zr), wherein some of the OR groups are substituted by complexing agents such as β-dicarbonyl compounds or monocarboxylic acids Can be. When a compound (methacrylic acid or the like) having a polymerizable unsaturated group is used as the complexing agent, a polymerizable unsaturated group can be introduced.

Water and / or organic solvents are preferably used as the dispersion medium. Particularly preferred dispersion medium is distilled (pure) water. As organic solvents, polar and nonpolar and aprotic solvents are preferred. Examples thereof include alcohols such as aliphatic alcohols having 1 to 6 carbon atoms (particularly methanol, ethanol, n- and i-propanol and butanol), ketones such as acetone and butanone and esters such as ethyl acetate; Ethers such as diethyl ether, tetrahydrofuran and tetrahydropyran; Amides such as dimethylacetamide and dimethylformamide; Sulfoxides and sulfones such as sulfolane and dimethyl sulfoxide; And aliphatic (optionally halogenated) hydrocarbons such as pentane, hexane and cyclohexane. These dispersion mediums can be used as a mixture.

It is preferable that the dispersion medium has a boiling point that can be easily removed by distillation (optionally under reduced pressure), and a solvent having a boiling point of 200 ° C. or lower, particularly 150 ° C. or lower is preferable.

When preparing the reactive inorganic fine particle A of (iii), the density | concentration of a dispersion medium is 40-90 normally, Preferably it is 50-80, Especially 55-75 weight%. The remainder of the dispersion is composed of untreated inorganic fine particles and the surface modification compound. Here, the weight ratio of the inorganic fine particles / surface modified compound is preferably 100: 1 to 4: 1, more preferably 50: 1 to 8: 1, and even more preferably 25: 1 to 10: 1. .

Preparation of the reactive inorganic fine particles A of (iii), Preferably it is performed at the boiling point of room temperature (about 20 degreeC)-a dispersion medium. Especially preferably, dispersion temperature is 50-100 degreeC. Dispersion time depends especially on the type of material used, but is generally several minutes to several hours, for example, 1 to 24 hours.

(Ii) The monomer obtained by dispersing the inorganic fine particles having a particle diameter of 5 nm or more and 80 nm or less in the hydrophobic vinyl monomer is discharged into the water through a hydrophilized porous membrane to make an aqueous dispersion of monomer droplets in which the inorganic fine particles are dispersed, and then polymerized. The inorganic fine particle which has a reactive functional group on the surface obtained.

In the case of using the reactive inorganic fine particles A of the above (ii), the monodispersity is further increased in terms of particle size distribution, and there is an advantage of suppressing the occurrence of irregular performance in the case of containing coarse particles.

Since the reactive inorganic fine particles A used in the present invention are inorganic fine particles having an organic component coated on at least part of the surface thereof and having a reactive functional group introduced by the organic component, a reactive inorganic fine particle A of type (ii) is produced. The hydrophobic vinyl monomer used for the polymerization at the time of containing at least contains the reactive functional group a or the thing which has the other reactive functional group which can introduce | transduce the desired reactive functional group a later. For example, after superposing | polymerizing using the thing which has a carboxyl group in hydrophobic vinyl monomer previously, glycidyl methacrylate is made to react by this carboxyl group, and introduce | transduces a polymerizable unsaturated group.

Specific examples of the hydrophobic vinyl monomer include aromatic vinyl compounds such as styrene, vinyltoluene, α-methylstyrene, and divinylbenzene; Methyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, t-butyl (meth) acrylate, n-hexyl (meth) acrylate, isobutyl (meth) acrylate, cyclohexyl (meth) acrylate, (meth) acrylic acid 2-ethylhexyl, lauryl (meth) acrylate, stearyl (meth) acrylate, benzyl (meth) acrylate, mono or di (meth) acrylate of (poly) ethylene glycol, mono or di () of (poly) propylglycol Unsaturated carboxylic acid esters such as meth) acrylate, mono- or di- (meth) acrylate of 1,4-butanediol, and mono-, di- or tri- (meth) acrylate of trimethylolpropane; Allyl compounds such as diallyl phthalate, diallyl acrylamide, triallyl (iso) cyanurate, triallyl trimellitate; (Poly) oxyalkylene glycol di (meth) acrylates, such as (poly) ethylene glycol di (meth) acrylate and (poly) propylene glycol di (meth) acrylate, etc. are mentioned. Moreover, conjugated diene compounds, such as butadiene, isoprene, and chloroprene, are mentioned. Furthermore, reactive functional group containing monomers, such as acrylic acid, methacrylic acid, itaconic acid, fumaric acid, glycidyl methacrylate, vinylpyridine, diethylaminoethyl acrylate, N-methylmethacrylamide, and acrylonitrile, are mentioned. . Among these, monomers having high water solubility, such as acrylic acid, methacrylic acid, and itaconic acid, can be used in a range in which the water solubility of the monomer as a whole becomes high and the oil-in-water monomer emulsion is not impossible.

The inorganic fine particles used in (ii) need to have a small particle diameter and to be well dispersed in a hydrophobic vinyl monomer. The particle diameter of the inorganic fine particles used here is 80 nm or less, Preferably it is 80 nm or less, More preferably, it is 70 nm or less. Moreover, when inorganic microparticles | fine-particles are inferior to a hydrophobic vinyl monomer, it is preferable to surface-treat an inorganic fine particle surface beforehand. For the surface treatment, a known method such as a dispersant treatment for adsorbing the pigment dispersant to the surface of the inorganic fine particles, a coupling agent treatment with a silane coupling agent, a titanate coupling or the like, or a polymer coat treatment by capsule polymerization or the like can be applied.

In (ii), in order to emulsify the hydrophobic vinyl monomer in which the inorganic fine particles are dispersed, it is discharged into water through a hydrophilized porous membrane. This porous pore needs to be an average pore diameter of 0.01-5 micrometers, a uniform pore diameter, and penetrate the front and back of a film | membrane. As the material of the film, glass is preferable. As a specific example, SiO ₂ -Al ₂ O ₃ -B ₂ O ₃ -CaO-based glass calcined with volcanic ash syras as a main raw material is microphase separated by heat treatment, and a phase rich in boric acid is obtained. Porous glass (called SPG) obtained by dissolving and removing with an acid is preferable.

In (ii), it is necessary to exist surfactant or a water-soluble polymer as a stabilizer of monomer droplets in the water phase which extrudes the hydrophobic vinyl monomer containing inorganic fine particles through a porous membrane. Without the stabilizer, the monomer droplets discharged through the membrane fuse together to form a wide particle size distribution. As a preferable stabilizer, when monomer droplets are about 1 micrometer or more, water-soluble high molecular stabilizers, such as polyvinyl alcohol, hydroxypropyl cellulose, polyvinylpyrrolidone, are preferable, and a small amount of anionic surfactant or nonionic emulsifier is added to this. It is also preferable to add. For example, the combination which uses sodium lauryl sulfate as an emulsifier and a 1-hexadecanol as a co-coating agent strongly adsorb | sucks to the droplet surface, and has a stabilizing effect, and it is especially preferable as a stabilizer in (ii).

In (ii), in order to superpose | polymerize the water dispersion of the monomer droplet containing the emulsified inorganic fine particle, an oil-soluble radical initiator is mainly used. Examples of initiators which can be used as oil-soluble radical initiators include azo initiators such as azobisisobutyronitrile, aromatic peroxides such as benzoyl peroxide and 2,4-dichlorobenzoyl peroxide, isobutyl peroxide and diisopropyl. Aliphatic peroxides, such as a peroxydicarbonate and di (2-ethylhexyl peroxy) dicarbonate, are mentioned. These can be used by dissolving in monomer phase before emulsification. Moreover, you may add water-soluble radical polymerization inhibitors, such as hydroquinone and iron chloride.

(Iii) a compound containing a reactive functional group to be introduced into the inorganic fine particles before coating, a group represented by the following formula (1), and a group which generates silanol groups by silanol or hydrolysis, and metal oxide fine particles as inorganic fine particles serving as a core; The inorganic fine particle which has a reactive functional group on the surface obtained by bonding to.

Formula (1)

-Q ¹ -C (= Q ² ) -NH-

(In Formula (1), Q ¹ represents NH, O (oxygen atom) or S (sulfur atom), and Q ² represents 0 or S).)

In the case of using the reactive inorganic fine particles A of (i) above, there is an advantage in that the amount of organic components is increased, and the dispersibility and film strength are further increased.

First, a compound containing a reactive functional group to be introduced into the inorganic fine particles before coating, a group represented by the above formula (1), and a silanol group or a group generating a silanol group by hydrolysis (hereinafter referred to as a reactive functional group-modified hydrolyzable silanol) May be used).

In the reactive functional group-modified hydrolyzable silane, the reactive functional group a to be introduced into the inorganic fine particles is not particularly limited as long as it is appropriately selected so as to react with the binder component C. It is suitable for introducing a polymerizable unsaturated group as described above.

In the reactive functional group-modified hydrolyzable silane, the group [-Q ¹ -C (= Q ² ) -NH-] represented by the formula (1) is specifically [-OC (= O) -NH-], [-OC (= S) -NH-], [-SC (= O) -NH-], [-NH-C (= O) -NH-], [-NH-C (= S) -NH- ] And [-SC (= S) -NH-].

These groups can be used individually by 1 type or in combination of 2 or more type. Especially, at least 1 type of a [-OC (= O) -NH-] group, a [-OC (= S) -NH-] group, and a [-SC (= O) -NH-] group from a thermal stability viewpoint. Preference is given to using. The group [-Q ¹ -C (= Q ² ) -NH-] represented by the above formula (1) generates an excellent cohesive force due to hydrogen bonding between molecules to form a cured product. It is thought that it becomes possible to provide characteristics, such as adhesiveness and heat resistance.

Moreover, as group which produces a silanol group by hydrolysis, the group which has an alkoxy group, an aryloxy group, an acetoxy group, an amino group, a halogen atom, etc. on a silicon atom is mentioned, Alkoxy silyl group or an aryloxy silyl group is preferable. Do. The group which produces a silanol group by a silanol group or hydrolysis can couple | bond with metal oxide fine particle by the condensation reaction which follows condensation reaction or hydrolysis.

As a preferable specific example of the said reactive functional group modified hydrolyzable silane, the compound represented by following General formula (2) is mentioned, for example.

Formula (2)

[Formula 1]

In Formula (2), R ^a and R ^b may be the same or different, and are a hydrogen atom or an alkyl group or an aryl group of C ₁ to C ₈ , for example, methyl, ethyl, propyl, butyl, octyl, phenyl, xyl And a reel group. Where m is 1, 2 or 3.

Examples of the group represented by [(R ^a O) _m R ^b _3-m Si-] include trimethoxysilyl group, triethoxysilyl group, triphenoxysilyl group, methyldimethoxysilyl group, and dimethylmethoxy Silyl groups; and the like. Among these groups, trimethoxysilyl group, triethoxysilyl group, and the like are preferable.

R ^C is a divalent organic group having an aliphatic or aromatic structure of C ₁ to C ₁₂ , and may contain a chain, branched or cyclic structure. Examples of such organic groups include methylene, ethylene, propylene, butylene, hexamethylene, cyclohexylene, phenylene, xylylene, dodecamethylene and the like. Preferred examples of these are methylene, propylene, cyclohexylene, phenylene and the like.

Moreover, R <^d> is a divalent organic group, Usually, it is selected from the bivalent organic group of 14-10,000 molecular weight normally, Preferably it is the molecular weight 76-500. For example, Chain polyalkylene groups, such as hexamethylene, octamethylene, and dodecamethylene; Alicyclic or polycyclic divalent organic groups such as cyclohexylene and norbornylene; Divalent aromatic groups such as phenylene, naphthylene, biphenylene and polyphenylene; And alkyl group substituents and aryl group substituents thereof. Moreover, these divalent organic groups may contain the atomic group containing elements other than carbon and a hydrogen atom, and are a polyether bond, a polyester bond, a polyamide bond, a polycarbonate bond, and also the group shown by the said General formula (1) It may contain.

R ^e is a (n + 1) valent organic group, preferably selected from chained, branched or cyclic saturated hydrocarbon groups and unsaturated hydrocarbon groups.

Y 'represents a monovalent organic group which has a reactive functional group. The reactive functional group itself as mentioned above may be sufficient. For example, when the reactive functional group a is selected from a polymerizable unsaturated group, a (meth) acryloyl (oxy) group, vinyl (oxy) group, propenyl (oxy) group, butadienyl (oxy) group, styryl (Oxy) group, ethynyl (oxy) group, cinnamoyl (oxy) group, a maleate group, a (meth) acrylamide group, etc. are mentioned. Moreover, n is preferably a positive integer of 1-20, More preferably, it is 1-10, Especially preferably, it is 1-5.

As a synthesis | combination of the reactive functional group modified hydrolyzable silane used by this invention, the method of Unexamined-Japanese-Patent No. 9-100111 can be used, for example. That is, for example, when it is going to introduce a polymerizable unsaturated group, (a) it can carry out by addition reaction of a mercaptoalkoxysilane, a polyisocyanate compound, and the active hydrogen group containing polymeric unsaturated compound which can react with an isocyanate group. have. Moreover, (b) It can carry out by the direct reaction of the compound which has an alkoxy silyl group and an isocyanate group in a molecule | numerator, and an active hydrogen group containing polymeric unsaturated compound. Moreover, it can also synthesize | combine directly by addition reaction of the compound which has a polymerizable unsaturated group and an isocyanate group in (c) molecule | numerator, and mercaptoalkoxysilane or aminosilane.

In the production of the reactive inorganic fine particles A of (iii), after the reactive functional group-modified hydrolyzable silane is subjected to a hydrolysis operation separately, this and inorganic fine particles are mixed to perform a heating and stirring operation, or a reactive functional group-modified valence. The surface of the inorganic fine particles in the presence of another method, for example, a polyunsaturated organic compound, a monovalent unsaturated organic compound, a radiation polymerization initiator, or the like, in which hydrolyzable silane is hydrolyzed in the presence of inorganic fine particles. Although the method of performing a process can be selected, the method of performing hydrolysis of a reactive functional group modified hydrolyzable silane in presence of an inorganic fine particle is preferable.

When manufacturing the reactive inorganic fine particle A of (iii), the temperature is 20 degreeC or more and 150 degrees C or less normally, and processing time is the range of 5 minutes-24 hours.

In order to accelerate the hydrolysis reaction, an acid, a salt or a base may be added as a catalyst. Examples of the acid include organic acids and unsaturated organic acids, and bases include tertiary amines and quaternary ammonium hydroxides. The addition amount of these acid or base catalysts is 0.001-1.0 weight% with respect to a reactive functional group hydrolyzable silane, Preferably it is 0.01-0.1 weight%.

Although the powdery fine particles which do not contain a dispersion medium may be used as the reactive inorganic fine particles A, the dispersion step can be omitted, and in view of high productivity, it is preferable to use those having fine particles as the solvent dispersion sol.

It is preferable that it is 5-70 weight% with respect to total solid, and, as for content of the reactive inorganic fine particle A, it is more preferable that it is 10-50 weight%. If it is less than 5 wt%, the hardness of the surface of the hard coat layer may be insufficient, and if it is more than 70 wt%, the interfacial adhesion between the hard coat layer and the transparent base film may be insufficient.

Hydrophilic Fine Particles B

In the present specification, the hydrophilic fine particles B may be either organic or inorganic. As an example of the hydrophilic microparticles | fine-particles B used for this invention, organic microparticles | fine-particles which introduce | transduced hydrophilic functional groups, such as a hydroxyl group, on the surface besides inorganic microparticles | fine-particles, such as a silica and an alumina, are mentioned. In the case of an organic system, the high molecular compound (polymer microparticles | fine-particles) which have a siloxane bond as a frame | skeleton and have an organic group are shown. As an organic group, a polyether group, a polyester group, an acryl group, a urethane group, an epoxy group, etc. can be illustrated besides the hydrocarbon group containing or not containing a hetero atom.

Hydrophilic microparticles | fine-particles B are microparticles | fine-particles which form a desired uneven | corrugated shape on the hard-coat layer surface, and contain in a hard-coat layer in order to prevent adhesion of the hard-coat layer surface. In addition, the shape of the hydrophilic fine particles B may be substantially spherical, for example, a spherical shape, a spheroidal shape, or the like, and more preferably a spherical shape.

In the present invention, the fine particles for forming a desired uneven shape on the surface of the hard coat layer are limited to the hydrophilic fine particles B as follows.

The hydrophilic fine particles B are fine particles having a hydrophilic surface, and in a small amount of addition, the hydrophilic fine particles B can coexist in the reactive inorganic fine particles A and the hard coat layer without affecting the film strength or transparency. When present in the vicinity of the surface, particles are extruded to the surface to form a fine concavo-convex shape on the surface. However, the particles themselves are present on the surface in a state of being coated with a binder resin or the like.

The average primary particle diameter of the hydrophilic fine particles B used in the present invention is 100 nm or more and 300 nm or less from the viewpoint of maintaining transparency, and particularly preferably 100 nm or more and 200 nm or less. In the case of less than 100 nm, there is a possibility that the unevenness which is effective in preventing adhesion may not be formed, and in the case of more than 300 nm, the transparency may be impaired.

The hydrophilic fine particles B may be agglomerated particles, and in the case of agglomerated particles, not only the primary particle diameter but also the secondary particle diameter may be within the above range.

The hydrophilic fine particles B tend to have low affinity with the ionizing radiation curable resin, and the diffusion rate of the hydrophilic fine particles B tends to be large, and thus the reasons described in paragraphs <51> to <55>, in particular (ii) As a result, a desired uneven shape can be formed on the surface of the hard coat layer.

Although content of the said hydrophilic microparticles | fine-particles B is 0.1-5.0 weight% with respect to total solid content, Especially preferably, it is 0.3-3.0 weight%. When it is less than 0.1 weight%, there is a possibility that an effect may not be expressed because it is too small, and when it is more than 5.0 weight%, transparency of a hard coat layer is reduced.

Curing Reactivity Matrix

In the present specification, the constituent components of the curable reactive matrix are the matrix components of the hard coat layer after curing of the curable binder components other than the binder component C, the polymer component, the polymerization initiator, and the like, if necessary.

[Binder component C]

In the curable resin composition for hard coat layers according to the present invention, the binder component C has a reactive functional group c having a crosslinking reactivity with the reactive functional group a of the reactive inorganic fine particles A, and the reactive functional group a and the reactive functional group c crosslink with each other. A net structure is formed. Moreover, in order for the binder component C to acquire sufficient crosslinking | crosslinked property, it is preferable to have three or more reactive functional groups c. As this reactive functional group c, a polymerizable unsaturated group is used preferably, Preferably it is a photocurable unsaturated group, Especially preferably, it is an ionizing radiation curable unsaturated group. As the specific example, ethylenic double bonds, such as a (meth) acryloyl group, a vinyl group, and an allyl group, are mentioned.

As binder component C, it is preferable that it is translucent to which light permeates when it coats, and the specific example is ionizing radiation curable resin, ionizing radiation curable resin, and solvent drying type resin which are resins hardened by ionizing radiation represented by an ultraviolet-ray or an electron beam. Three kinds of mixtures (resin which becomes a film | membrane only by drying the solvent for adjusting solid content at the time of coating, such as a thermoplastic resin), or thermosetting resin are mentioned, Preferably an ionizing radiation curable resin is mentioned. .

As a specific example of ionizing radiation curable resin, the compound which has radically polymerizable functional groups, such as a (meth) acrylate group, for example, a (meth) acrylate type oligomer, a prepolymer, or a monomer (monomer) is mentioned. More specifically, as a (meth) acrylate type oligomer or prepolymer, it is comparatively low molecular weight polyester resin, a polyether resin, an acrylic resin, an epoxy resin, a urethane resin, an alkyd resin, a spiro acetal resin, a polybutadiene resin, The oligomer or prepolymer which consists of (meth) allylic acid ester of polyfunctional compounds, such as a polythiol polyene resin and a polyhydric alcohol, is mentioned. Moreover, as a (meth) acrylate type monomer, ethyl (meth) acrylate, ethylhexyl (meth) acrylate, hexanediol (meth) acrylate, hexanediol (meth) acrylate, and tripropylene glycol di (meth) acryl Rate, diethylene glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, pentaerythritol tree ( Meth) acrylate, dipentaerythritol hexa (meth) acrylate, and the like.

Examples other than the (meth) acrylate-based compound include monofunctional or polyfunctional monomers such as styrene, methyl styrene and N-vinylpyrrolidone, or bisphenol type epoxy compounds, novolac type epoxy compounds, aromatic vinyl ethers and aliphatic vinyls. The compound which has cationic polymerizable functional groups, such as oligomers, such as ether, or a prepolymer, is mentioned.

When using ionizing radiation curable resin as an ultraviolet curable resin, a sensitizer can be added as a photoinitiator or a photoinitiator.

As a specific example of a photoinitiator, in the case of resin system which has a radically polymerizable functional group, acetophenone, benzophenone, Michler's benzoyl benzoate, (alpha)-amyl oxime ester, tetramethyl thiuram monosulfide, benzoin, Benzoin methyl ether, thioxanthones, propiophenones, benzyl, acylphosphine oxides, 1-hydroxy-cyclohexyl-phenyl-ketone, and the like. These may be used alone or in combination. 1-hydroxycyclohexyl-phenyl-ketone can be obtained, for example, under the trade name Irgacure 184 (manufactured by Chiba Specialty Chemicals). Moreover, as (alpha)-aminoalkyl phenones, it can obtain as brand names Irgacure 907, 369, for example.

In the case of the resin system having a cation polymerizable functional group, an aromatic diazonium salt, an aromatic sulfonium salt, an aromatic iodonium salt, a metacerone compound, a benzoin sulfonic acid ester, or the like is used as a photopolymerization initiator alone or as a mixture.

Moreover, it is preferable to mix and use a photosensitizer, and specific examples thereof include n-butylamine, triethylamine, poly-n-butylphosphine, and the like.

The addition amount of a photoinitiator is 0.1-10 weight part with respect to 100 weight part of ionizing radiation curable compositions.

As a solvent-drying resin used by mixing with an ionizing radiation curable resin, a thermoplastic resin is mainly mentioned. Thermoplastic resins are generally used. Due to the addition of the solvent-drying resin, coating film defects on the coated surface can be effectively prevented. As a specific example of a preferable thermoplastic resin, a styrene resin, (meth) acrylic-type resin, organic acid vinyl ester resin, vinyl ether resin, halogen-containing resin, olefin resin (The alicyclic olefin resin is contained, for example. ), Polycarbonate resin, polyester resin, polyamide resin, thermoplastic polyurethane resin, polysulfone resin (e.g. polyethersulfone, polysulfone), polyphenylene ether resin (e.g. , Polymers of 2,6-xylenol), cellulose derivatives (e.g., cellulose esters, cellulose carbamates, cellulose ethers), hydrophilic resins (e.g., polydimethylsiloxane, polymethylphenylsiloxane), Rubbers or elastomers (for example, diene rubbers such as polybutadiene, polyisoprene, styrene-butadiene copolymers, acrylonitrile-butadiene copolymers, arcs) Reel rubber, urethane rubber, silicone rubber) and the like.

Specific examples of the thermosetting resin include phenol resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, unsaturated polyester resins, polyurethane resins, epoxy resins, aminoalkyd resins, melamine-urea cocondensation resins and silicon. Resin, polysiloxane resin, and the like. When using a thermosetting resin, the crosslinking agent, hardening | curing agents, such as a polymerization initiator, a polymerization promoter, a solvent, a viscosity modifier, etc. can be further added and used as needed.

Curable Binder Component

Moreover, the compound which has two or less reactive functional groups c is applicable as a curable binder component, Specifically, polyethyleneglycol diacrylate, triethylene glycol diacrylate, ethylene glycol diacrylate, polypropylene glycol diacrylate, poly Ether diacrylate, dipropylene glycol diacrylate, bisphenol A epoxy acrylate, bisphenol F epoxy acrylate, 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, 1,4-butanediol di Acrylate, 1, 9-nonane diol diacrylate, trimethylol propane diacrylate, tricyclodecane dimethanol diacrylate, pentaerythritol diacrylate monostearate, isocyanuric acid diacrylate, etc. are mentioned. .

It is preferable that a number average molecular weight is 1000 or less with (meth) acrylate containing a polar group (OH group etc.), For example, pentaerythritol triacrylate and dipentaerythritol tetraacrylate are preferable.

Since such compounds are excellent in dispersibility of moderately hydrophobized reactive inorganic fine particles A and form a dense network structure having a short distance between crosslinking points, the hydrophilic fine particles B present near the surface of the cured film due to the volume exclusion effect It becomes possible to efficiently localize (to within 300 nm from an air interface).

[Polymer component]

Moreover, as a "polymer component", what is called a macromer which has a reactive group in the terminal and both terminal is mentioned.

<Other ingredients>

Examples of the solvent include alcohols such as methanol, ethanol, isopropyl alcohol, butanol, isobutyl alcohol, methyl glycol, methyl glycol acetate, methyl cellosolve, ethyl cellosolve, and butyl cellosolve; Ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone and diacetone alcohol; Esters such as methyl formate, methyl acetate, ethyl acetate, ethyl lactate, and butyl acetate; Nitrogen-containing compounds such as nitromethane, N-methylpyrrolidone and N, N-dimethylformamide; Ethers such as diisopropyl ether, tetrahydrofuran, dioxane and dioxolane; Halogenated hydrocarbons such as methylene chloride, chloroform, trichloroethane and tetrachlorethane; Others, such as dimethyl sulfoxide and propylene carbonate; Or mixtures thereof. Methyl acetate, ethyl acetate, butyl acetate, methyl ethyl ketone etc. are mentioned as a more preferable solvent.

Curable resin composition for hard-coat layers which concerns on this invention may contain antistatic preparation and an anti-glare agent further. Moreover, various additives, such as a reactive or non-reactive leveling agent and various sensitizers, may be mixed. When it contains an antistatic agent and / or an antiglare agent, the curable resin composition for hard coat layers which concerns on this invention can further provide antistatic property and / or anti-glare property.

<Preparation of resin composition>

Curable resin composition for hard-coat layers which concerns on this invention is prepared by mixing and disperse | distributing the said component according to the general preparation method. A paint shaker or bead mill can be used for the mixed dispersion. When the reactive inorganic fine particles A and the hydrophilic fine particles B are obtained in a dispersed state in a solvent, they are prepared by appropriately adding, mixing and dispersing the cured reactive matrix and other components containing the solvent in the dispersed state.

Although it does not specifically limit as a density | concentration of solid content in the curable resin composition for hard-coat layers which concerns on this invention, Usually, it exists in the range of 5 weight%-40 weight%, especially the range of 15 weight%-30 weight%. desirable.

II. Hardcoat film

The hard coat film which concerns on this invention is provided with the hard coat layer which consists of hardened | cured material of the curable resin composition for hard coat layers which concerns on the said invention on a transparent base film at least, and further has 1 or 2 or more resin layers on it. It may be laminated.

ADVANTAGE OF THE INVENTION According to this invention, by providing the hard-coat layer which consists of hardened | cured material of the curable resin composition for hard-coat layers which concerns on the said invention on a transparent base film, the hard-coat layer does not impair transparency and scratch resistance, The hard coat film which provided the uneven | corrugated shape desired to the coating layer surface can be provided.

Moreover, in the hard coat film which concerns on this invention, the hydrophilic microparticles | fine-particles B in the hard-coat layer have the convex part of height 50 nm or less larger than 3 nm in the said hard-coat layer surface, and the space | interval of convex parts is 50 nm. It is characterized by forming the unevenness | corrugation which is-5 micrometers.

According to this invention, since it forms in the desired uneven | corrugated shape on the said hard-coat layer surface, when the said hard-coat film is wound continuously in a continuous strip form and it is set as a long roll, the surface of the hard-coat layer side of the hard-coat film And adhesion of the surface of the hard coat film on the base film side can be prevented.

It is sectional drawing which shows an example of the hard coat film of this invention. In addition, in FIG. 2, the thickness direction (up-down direction of drawing) is greatly expanded and exaggerated rather than the scale of the surface direction (left-right direction of drawing) for the ease of description. In the example shown in FIG. 2, the hard-coat layer 2 which consists of hardened | cured material of the curable resin composition for hard-coat layers which concerns on said this invention is laminated | stacked on one surface side of the transparent base film 1, The hard coat The surface of the layer 2 is formed in an uneven shape.

Hereinafter, each layer which comprises the hard coat film of this invention is demonstrated in order.

<Transparent base film>

Although the material of a transparent base film is not specifically limited, The general material used for a hard-coat film can be used, For example, what mainly uses a cellulose acylate, a cycloolefin polymer, an acrylate polymer, or polyester is mentioned. have. Here, "mainly" means the component with the highest content rate among the base material structural components.

Specific examples of the cellulose acylate include cellulose triacetate, cellulose diacetate, cellulose acetate butyrate, and the like. As a cycloolefin polymer, a norbornene-type polymer, a monocyclic cyclic olefin type polymer, a cyclic conjugated diene type polymer, a vinyl alicyclic hydrocarbon type polymer resin, etc. are mentioned, For example, Nippon Xeon ( ZEONEX Co., Ltd. (Norbornene-based resin), Sumitomo backlight Co., Ltd. Sumilite FS-1700, ASR (Modified Norbornene-based resin), JSR Co., Ltd., Mitsui Chemical Co., Ltd. Aper (cyclic olefin copolymer), Topas (cyclic olefin copolymer) by Ticona Corporation, Optorets OZ-1000 series (alicyclic acrylic resin) by Hitachi Chemical Co., etc. are mentioned. As a specific example of an acrylate polymer, methyl poly (meth) acrylate, ethyl poly (meth) acrylate, a methyl (meth) acrylate- butyl (meth) acrylate copolymer, etc. are mentioned. Here, (meth) acryl means acryl, methacryl, and the mixed system of both. Specific examples of the polyester include polyethylene terephthalate and polyethylene naphthalate.

The thickness of a transparent base film is 20 micrometers or more and 300 micrometers or less, Preferably they are 30 micrometers or more and 200 micrometers or less. In this invention, when forming a hard-coat layer on a transparent base film, in addition to the physical treatments, such as a corona discharge treatment and an oxidation treatment, in order to improve adhesiveness, you may apply previously the coating material called an anchor agent or a primer.

<Hard coat layer>

The hard coat layer used in the present invention is a reactive inorganic fine particle A for imparting hard coat properties, a hydrophilic fine particle B for forming irregularities on the surface of the hard coat layer, and reducing adhesion of the surface, and a substrate or adjacent A binder component C for imparting adhesion to the layer as an essential component, comprising a component of a cured reactive matrix which forms a matrix of the hard coat layer after curing, the hard coat layer being directly or through another layer. It is formed on a transparent base film.

A "hard coat layer" generally shows the hardness of "H" or more by the pencil hardness test prescribed | regulated by JISK5600-5-4 (1999). Although the hardness is a value depending on the kind and thickness of the said base film, it is not limited to what is suitably selected according to a use and a required performance, but the hard-coat layer used for this invention is 2H or more from the pencil hardness test, It is especially preferable that it is 3H or more. Moreover, it is preferable that the film thickness of this hard-coat layer is 1 micrometer or more and 50 micrometers or less from a viewpoint of abrasion resistance, and it is especially preferable that they are 5 micrometers or more and 30 micrometers or less, Furthermore, 5 micrometers or more and 20 micrometers or less.

Moreover, in this invention, although the height of the uneven | corrugated convex part of the said hard-coat layer surface is 3 nm or more and 50 nm or less, Especially preferably, they are 5 nm or more and 20 nm or less. When it is less than 3 nm, there exists a possibility that there may be no sticking prevention effect, and when it is more than 50 nm, there exists a possibility that a transparency may be damaged. Moreover, as for the space | interval of convex parts, 50 nm-5 micrometers are preferable. If the spacing is less than 50 nm, there is a risk of damaging the transparency. If it is larger than 5 mu m, it becomes difficult to obtain an anti-sticking effect.

<Other layers>

As mentioned above, the hard coat film by this invention is comprised by a transparent base film and a hard coat layer fundamentally. However, in addition to the function or use as a hard coat film, in addition to the hard coat layer which concerns on this invention, you may contain the following 1 or 2 or more layers further. Moreover, you may form including a medium refractive index layer and a high refractive index layer.

(1) antistatic layer

The antistatic layer contains an antistatic agent and a resin. It is preferable that the thickness of an antistatic layer is about 30 nm-1 micrometer.

Specific examples of the antistatic agent include various cationic compounds having cationic groups such as quaternary ammonium salts, pyridinium salts, and first to third amino groups, sulfonate groups, sulfate ester groups, phosphate ester bases, and phosphonate groups. Anionic compounds having an anionic group, anionic compounds such as amino acids, aminosulfate esters, nonionic compounds such as aminoalcohols, glycerins, and polyethylene glycols, and organic metals such as alkoxides of tin and titanium The metal chelate compound, such as a compound and these acetylacetonate salts, etc. are mentioned, The compound which carried out high molecular weight of the compound mentioned above is mentioned. Moreover, it has a tertiary amino group, a quaternary ammonium group metal chelate part, and has a monomer or oligomer which can superpose | polymerize by ionizing radiation, or a polymerizable functional group which can superpose | polymerize by ionizing radiation, and is organic, such as a coupling agent. Polymeric compounds, such as a metal compound, can also be used as an antistatic agent.

Moreover, electroconductive fine particles are mentioned as another example of the said antistatic agent. As a specific example of the electroconductive fine particles, what consists of metal oxides is mentioned. Such metal oxides are often abbreviated as ZnO (refractive index 1.90, numerical values in parentheses indicate refractive index), CeO ₂ (1.95), Sb ₂ O ₂ (1.71), SnO ₂ (1.997), and ITO. Indium tin oxide (1.95), In ₂ O ₃ (2.00), Al ₂ O ₃ (1.63), antimony dope tin oxide (abbreviated; ATO, 2.0), aluminum dope zinc oxide (abbreviated; AZO, 2.0), and the like. have. It is preferable that the average particle diameter of the said electroconductive fine particles is 0.1 nm-0.1 micrometer. When it is in this range, when the said electroconductive fine particle is disperse | distributed to a binder, the composition which can form the highly transparent film | membrane which is almost free of haze and whose total light transmittance is favorable is obtained.

As a specific example of resin contained in an antistatic layer, a thermoplastic resin, a thermosetting resin, or a photocurable resin or a photocurable compound (containing an organic reactive silicon compound) can be used. Although thermoplastic resin can also be used as resin, it is more preferable to use a thermosetting resin, More preferably, it is a photocurable composition containing a photocurable resin or a photocurable compound.

As a photocurable composition, the prepolymer, oligomer, and / or monomer which have a polymerizable unsaturated group or an epoxy group in a molecule | numerator is mixed suitably.

As an example of the prepolymer, oligomer, and monomer in a photocurable composition, the thing similar to what was mentioned in the said hard coat layer can be used.

Usually, as a monomer in a photocurable composition, 1 type (s) or 2 or more types are mixed and used as needed, In order to provide normal coating suitability to a photocurable composition, the said prepolymer or oligomer is 5 weight% or more, The said It is preferable to make a monomer and / or a polythiol compound into 95 weight% or less.

(2) low refractive index layer

The low refractive index layer is composed of a silica or a resin containing magnesium fluoride, a fluorine resin containing a low refractive index resin, a silica, or a fluorine resin containing a magnesium fluoride, and having a refractive index of 1.46 or less, a thin film of about 30 nm to 1 μm, Alternatively, the thin film may be formed by chemical vapor deposition or physical vapor deposition of silica or magnesium fluoride. About resins other than a fluororesin, it is the same as resin used to comprise an antistatic layer.

The low refractive index layer is more preferably composed of a silicon-containing vinylidene fluoride copolymer. Specifically, the silicone-containing vinylidene fluoride copolymer is composed of a monomer composition containing 30 to 90% of vinylidene fluoride and 5 to 50% of hexafluoropropylene (after which the percentage is based on weight). It is obtained by one copolymerization, and is a resin composition which consists of 100 parts of fluorine-containing copolymers with 60-70% of fluorine content rates, and 80-150 parts of polymeric compounds which have an ethylenically unsaturated group, and use this resin composition and the film thickness 200 A low refractive index layer having a refractive index of less than 1.60 (preferably 1.46 or less) which is a thin film of nm or less and which is provided with scratch resistance.

In addition, the low refractive index layer may be composed of a thin film made of SiO ₂ , and may be formed by a vapor deposition method, a sputtering method, a plasma CVD method, or the like, or by a method of forming a SiO ₂ gel film from a sol solution containing a SiO ₂ sol. do. The low refractive index layer may be formed of a thin film of MgF ₂ or other materials in addition to SiO ₂ , but it is preferable to use a SiO ₂ thin film in view of high adhesion to the underlying layer.

According to the preferable aspect of the low refractive index layer of this invention, it is preferable to use "fine particle which has a space | gap."

"Microparticles with voids" makes it possible to lower the refractive index while maintaining the layer strength of the low refractive index layer. The term "fine particles having voids" refers to a fine particle having a structure filled with a gas and / or a porous structure containing a gas inside the fine particles, and having a refractive index lowering in inverse proportion to the share of the gas in the fine particles as compared to the original refractive index of the fine particles. it means. Moreover, in this invention, the microparticles | fine-particles which can form a nanoporous structure in at least one part inside and / or the surface are also contained by the form, structure, agglomeration state, and the dispersion state of microparticles | fine-particles in a coating film inside.

The average particle diameter of the "fine particles having voids" is 5 nm or more and 300 nm or less, Preferably a minimum is 8 nm or more and an upper limit is 80 nm or less, More preferably, a minimum is 10 nm or more and an upper limit is 80 nm or less to be. When the average particle diameter of microparticles | fine-particles exists in this range, it becomes possible to give the low refractive index layer excellent transparency.

(3) antifouling layer

According to a preferred embodiment of the present invention, an antifouling layer may be formed for the purpose of preventing contamination of the surface of the low refractive index layer. The antifouling layer can be made to further improve the antifouling property and the scratch resistance to the hard coat film.

Specific examples of the antifouling agent include a fluorine-based compound and / or a silicon-based compound having low compatibility with a photocurable resin composition having a fluorine atom in a molecule and becoming difficult to add in the low refractive index layer. The fluorine type compound and / or the silicon type compound which are compatible with a chemical conversion resin composition and microparticles | fine-particles are mentioned.

Hereinafter, the manufacturing method of the hard coat film of this invention is demonstrated.

First, the transparent base film mentioned in the description of the hard coat film mentioned above is prepared. Next, the curable resin composition for hard coat layers which concerns on this invention is prepared. Next, the obtained curable resin composition for hard-coat layers is apply | coated and dried on a transparent base film.

The coating method is not particularly limited as long as it is a method capable of uniformly applying the resin composition for forming a hard coat layer on the surface of the transparent base film, and the spin coating method, the dipping method, the spray method, the die coating method, the bar coating method, and the roll coater method. Various methods, such as the meniscus coater method, the flexographic printing method, the screen printing method, the feed coater method, can be used.

Moreover, as a coating amount on a transparent base film, although the hard coat film obtained differs by the performance calculated | required, in the range of 1 g / m <2> -30g / m <2>, the coating amount after drying is especially 5g / m <2> -25g / m <2>. It is preferable to exist in the range. Speaking of film thickness, it is preferable to exist in the range of 1 micrometer-25 micrometers, especially the range of 5 micrometers-20 micrometers. Coating film thickness measures the whole film thickness with a contact-type film | membrane meter, and calculate | requires the measured value of the film thickness as much as the transparent base film used there.

As a drying method, the method of combining vacuum drying, heat drying, these drying, etc. are mentioned, for example. For example, when using a ketone solvent as a solvent, it is usually 20 second-3 minutes at the temperature within the range of room temperature-80 degreeC, Preferably 40 degreeC-60 degreeC, Preferably about 30 second-1 minute The drying process is performed for a time.

In addition, the reactive inorganic fine particles A and the hydrophilic fine particles B uniformly dispersed in the curable resin composition for the hard coat layer are ubiquitous in the vicinity of the interface on the transparent base film side in the drying step, and the hydrophilic fine particles B are It is ubiquitous in the interface vicinity on the opposite side to the transparent base film side.

Next, with respect to the coating film which apply | coated and dried the said curable resin composition for hard-coat layers, it irradiates and / or heats according to the reactive functional group contained in this curable resin composition, and hardens a coating film in the structural component of this curable resin composition. The reactive functional group a of the said reactive inorganic fine particles A and the reactive functional group c of the said binder component C contained are bridge | crosslinked, and the hard-coat layer which consists of hardened | cured material of this curable resin composition is formed. Moreover, the hydrophilic microparticles | fine-particles B in the structural component of this curable resin composition are fixed, a desired uneven | corrugated shape is formed in the surface of a hard cord layer, and the hard coat film of this invention is obtained.

Ultraviolet rays, visible light, an electron beam, ionizing radiation, etc. are mainly used for light irradiation. In the case of ultraviolet curing, ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, ultraviolet rays emitted from light rays such as carbon arcs, xenon arcs, and metal halide lamps are used. The irradiation amount of an energy source is about 50-5000mJ / cm <2> as an integrated exposure amount in an ultraviolet-ray wavelength 365nm.

Moreover, in the case of ultraviolet curing, when oxygen exists, hardening of the surface may be insufficient. Depending on the combination of materials to be used, when the surface becomes insufficiently hardened, hardening proceeds from the inside, so that the degree of the hydrophilic fine particles B being extruded from the inside to the surface may increase, and in such a case, the height of the convex portion becomes excessive. It may become white. Since the height of the convex part increases, the prevention of close bonding between mirror surfaces becomes good, but the durability against a saponification, scratch resistance, and optical properties deteriorate. Therefore, in order to reduce this oxygen inhibition, the hardened | cured side becomes possible hardening while carrying out purge with nitrogen.

When heating, it usually processes at the temperature of 40 degreeC-120 degreeC. Moreover, you may react by leaving at room temperature (25 degreeC) for 24 hours or more.

The anti-sticking effect of the hard coat film is exhibited either in the case of the roll-like long film used in the roll-to-roll process or in the case of the single sheet film, but in the present invention, when wound into a roll in the form of the long film It also exhibits an excellent anti-sticking effect on the adhesion near the roll center. Therefore, the hard coat film which concerns on this invention is suitable for using continuously in the form of a roll-shaped elongate film wound continuously in a continuous strip | belt-shaped state.

In addition, this invention is not limited to the said embodiment. The said embodiment is an illustration, Any thing which has a structure substantially the same as the technical idea described in the claim of this invention, and shows the same effect is included in the technical scope of this invention.

Example

Hereinafter, an Example is shown and this invention is demonstrated concretely. These descriptions do not limit the present invention. In addition, in an Example, a part shows a weight part unless there is particular notice.

(Manufacture example 1: preparation of reactive inorganic fine particle A (1))

(1) surface adsorption ion removal

400 g of water-disperse colloidal silica (Snotechs XL, trade name, manufactured by Nissan Chemical Industries, Ltd., pH 9-10) with an average particle diameter of cation exchange resin (Dionion SK1B, manufactured by Mitsubishi Chemical Corporation) Ion exchange was performed for 3 hours, and then ion exchange was performed for 3 hours using 200 g of anion exchange resin (Diaion SA20A, manufactured by Mitsubishi Chemical Co., Ltd.), followed by washing, followed by inorganic fine particles having a solid content of 40% by weight. An aqueous dispersion of was obtained.

At this time, the Na ₂ O content of the aqueous dispersion of the inorganic fine particles was 7 ppm per inorganic fine particle.

(2) Surface Treatment (Introduction of Monofunctional Monomer)

150 ml of isopropanol, 4.0 g of 3,6,9-trioxadecanoic acid and 4.0 g of methacrylic acid are added to 10 g of the aqueous dispersion of the inorganic fine particles treated with the above (1), and stirred and mixed for 30 minutes. It was.

By stirring the obtained liquid mixture at 60 degreeC for 5 hours, the inorganic fine particle dispersion liquid in which the methacryloyl group was introduce | transduced into the inorganic fine particle surface was obtained. The resulting inorganic fine particle dispersion was distilled off from distilled water and isopropanol using a rotary evaporator, and methyl ethyl ketone was added so as not to be dried. A 50 wt% silica dispersed methyl ethyl ketone solution was obtained.

The reactive inorganic fine particles A (1) thus obtained had an average particle diameter of d ₅₀ = 50 nm as measured by a Nikkiso Corporation Microtrac particle size analyzer.

(Manufacture example 2: preparation of reactive inorganic fine particle A (2))

Reactive inorganic fine particles A (2) in the same manner as in Production Example 1, except that water-disperse colloidal silica (Snotechs ZL, trade name, manufactured by Nissan Chemical Industries, Ltd., pH 9-10) having an average particle diameter was used. ) Was prepared. The reactive inorganic fine particles A (2) thus obtained had an average particle diameter of d ₅₀ = 80 nm as measured by a Nikkiso Corporation Microtrac particle size analyzer.

(Manufacture example 3: Preparation of reactive inorganic fine particle A (3))

(1) surface adsorption ion removal

In the same manner as in Production Example 1, an aqueous dispersion of inorganic fine particles from which surface adsorption ions were removed was obtained.

(2) surface treatment (introduction of polyfunctional monomer)

In Production Example 1, the surface treatment was carried out in the same manner as in Production Example 1, except that methacrylic acid was changed to dipentaerythritol pentaacrylate (SR399, trade name, manufactured by Satoma Co., Ltd.).

The reactive inorganic fine particles A (3) thus obtained had an average particle diameter of d ₅₀ = 52 nm as measured by the particle size analyzer.

(Manufacture example 4: preparation of reactive inorganic fine particle A (4))

Silica sol (organosilica sol, OSCAL, trade name, Shokubai Chemical Industries, Ltd., isopropyl alcohol dispersion) having an average particle diameter of 45 nm was converted from isopropyl alcohol to methyl isobutyl ketone using a rotary evaporator. Solvent substitution was performed and the dispersion liquid of 20 weight% of silica fine particles was obtained. 20 parts by weight of 3-methacryloxypropylmethyldimethoxysilane was added to 100 parts by weight of this methyl isobutyl ketone dispersion liquid and heated at 50 ° C. for 1 hour to give 20% by weight of methyl isobutyl ketone in surface-treated fine silica fine particles. Dispersion A (4) was obtained.

The reactive inorganic fine particles A (4) thus obtained had an average particle diameter of d ₅₀ = 45 nm as measured by a Nikkiso Corporation Microtrac particle size analyzer.

(Manufacture example 5: preparation of reactive inorganic fine particle A (5))

To a solution consisting of 7.8 parts of mercaptopropyltrimethoxysilane and 0.2 part of dibutyltin dilaurate in dry air, 20.6 parts of isophorone diisocyanate was added dropwise at 50 ° C for 1 hour, followed by stirring at 60 ° C for 3 hours. It was. 71.4 parts of pentaerythritol triacrylates were dripped at this at 30 degreeC for 1 hour, and the compound (1) was obtained by heating and stirring at 60 degreeC for 3 hours.

Methanol silicate (made by Nissan Chemical Industries, Ltd., brand name, methanol solvent colloidal silica dispersion (number average particle diameter 50nm, silica concentration 30%)) under nitrogen stream 88.5 parts (solid content 26.6 parts), synthesize | combined above The liquid mixture of 8.5 parts of compound (1) and 0.01 parts of p-methoxy phenol was stirred at 60 degreeC for 4 hours. Subsequently, 3 parts of methyl trimethoxysilanes are added to this mixed solution as a compound (2), and it stirred at 60 degreeC for 1 hour, and then, 9 parts of ortho formic acid methyl esters are added, and it heats and stirs at the same temperature again for 1 hour. Crosslinkable inorganic fine particles were obtained. The reactive inorganic fine particles A (5) thus obtained had an average particle diameter of d ₅₀ = 63 nm as measured by the particle size analyzer.

(Manufacture example 6 preparation of reactive inorganic fine particle A (6))

Silica sol (organosilica sol, OSCAL, trade name, Shokubai Chemical Industries, Ltd., isopropyl alcohol dispersion) having an average particle diameter of 5 nm was subjected to a solvent from isopropyl alcohol to methyl isobutyl ketone using a rotary evaporator. Substitution was performed and the dispersion liquid of 20 weight% of silica fine particles was obtained. 20 parts by weight of 3-methacryloxypropylmethyldimethoxysilane was added to 100 parts by weight of this methyl isobutyl ketone dispersion liquid and heated at 50 ° C. for 1 hour to give 20% by weight of methyl isobutyl ketone in surface-treated fine silica fine particles. Dispersion A (4) was obtained.

The reactive inorganic fine particles A (4) thus obtained had an average particle diameter of d ₅₀ = 6 nm when measured by a Nikkiso Corporation Microtrac particle size analyzer.

<Example 1>

(1) Preparation of curable resin composition for hard coat layers

Each component below was mixed, it adjusted to 50 weight% of solid content with the solvent, and the curable resin composition for hard coat layers was prepared.

<Composition of curable resin composition for hard coat layer>

UV1700B (trade name, manufactured by Nippon Synthetic Chemical Co., Ltd., 10 functional, molecular weight 2,000): 70 parts by weight (solid content equivalent)

Reactive inorganic fine particle A (1) (average particle diameter 50nm) of manufacture example (1): 30 weight part (solid content conversion value)

Methyl ethyl ketone: 100 parts by weight

Hydrophilic fine particle B silica sol (trade name IPA-ST-ZL, manufactured by Nissan Chemical Industries, Ltd., average particle diameter: 100 nm): 1 part by weight

Irgacure 184 (trade name, manufactured by Chiba Specialty Chemicals, radical polymerization initiator): 0.4 part by weight

(2) Production of hard coat film

WET weight 40g / m <2> (dry weight 20g / m <2>, about 15 micrometers) is apply | coated to the base material using 80 micrometer cellulose triacetate film as a transparent base film, and the curable resin composition for hard-coat layers prepared by (1) on the base material. It was. It dried for 30 second at 50 degreeC, the ultraviolet-ray 200mJ / cm <2> was irradiated, and the hard coat film of Example 1 was produced.

<Example 2-Example 16>

In curable resin composition for hard-coat layers, UV1700B, methyl ethyl ketone, and Irgacure 184 are the same amount, The reactive inorganic fine particle A and the hydrophilic fine particle B (silica) were mix | blended as Table 1 below, and the hard coat film was produced. In addition, as the hydrophilic fine particles B, silica (trade name Shihostar KE-P30, manufactured by Nippon Catalyst Co., Ltd.) having an average particle diameter of d ₅₀ = 250 nm was used in some cases.

<Example 17>

A hard coat film was obtained in the same manner as in Example 1 except that dipentaerythritol pentaacrylate (6-functional) was used for the binder component C.

Example 18

A hard coat film was obtained in the same manner as in Example 1 except that pentaerythritol triacrylate (trifunctional) was used for the binder component C.

Example 19

A hard coat film was obtained in the same manner as in Example 1 except that Beam Set 371 (manufactured by Arakawa Chemical Industry Co., Ltd., brand name, 50 functional or more) was used for the binder component C.

Example 20

In the manufacture of the hard coat film of Example 11, a hard coat film was obtained in the same manner as in Example 1 except that 5 parts by weight of hydrophilic fine particles B were added.

Comparative Example 1

In the production of the hard coat film of Example 1, in place of the reactive inorganic fine particles A, hydrophilic fine particles B (MEK-ST-L: trade name, manufactured by Nissan Chemical Industries, Ltd.) having an average particle diameter of d ₅₀ = 40 nm Except having used 51 weight part, it carried out similarly to Example 1, and obtained the hard-coat film.

Comparative Example 2

In the production of the hard coat film of Example 11, a hard coat film was obtained in the same manner as in Example 1 except that only the reactive inorganic fine particles A obtained in Production Example 5 were used.

Comparative Example 3

In the manufacture of the hard coat film of Example 11, instead of the hydrophilic fine particles B, 1 part by weight of silica beads (Shistar KE-P50: trade name, Nippon Catalyst Co., Ltd.) having an average particle diameter of d ₅₀ = 500 nm was used. A hard coat film was obtained in the same manner as in Example 1 except for the above.

<Comparative Example 4>

In the production of the hard coat film of Example 11, except that hydrophilic fine particles B were used, except that 1 part by weight of urethane beads (manufactured by Negami Industry Co., Ltd.) having an average particle diameter of d ₅₀ = 300 nm was used. In the same manner as in 1, a hard coat film was obtained.

Comparative Example 5

When content of hydrophilic microparticles | fine-particles B is more than an upper limit

In the manufacture of the hard coat film of Example 11, a hard coat film was obtained in the same manner as in Example 1 except that 6 parts by weight of hydrophilic fine particles B were added.

Comparative Example 6

Above the upper limit of the average primary particle diameter

(Manufacture example 7 preparation of reactive inorganic fine particle A (7))

The silica sol of Production Example 5 was the same as that except for using IPA dispersed colloidal silica (trade name IPA-ST-ZL; manufactured by Nissan Chemical Industries, Ltd., silica concentration 30%) having an average particle diameter of d ₅₀ = 100 nm. Reactive inorganic fine particles A (7) were obtained by the method.

In the production of the hard coat film of Example 11, a hard coat film was obtained in the same manner as in Example 1 except that the reactive inorganic fine particles A (7) were used.

Comparative Example 7

In the manufacture of the hard coat film of Example 20, urethane acrylate (UX8101D; Nippon Gunpowder Co., Ltd. product, bifunctional, weight average molecular weight 5000 or more) and pentaerythritol triacrylate (trifunctional) were added to the binder component C. A hard coat film was obtained in the same manner as in Example 1 except that resin mixed in 1: 1 was used.

As a sample for indentation depth test, the hard coat film of 20 micrometers of dry film thicknesses was manufactured separately.

The results of Comparative Examples 1 to 7 are shown in Table 2 below.

〔Assessment Methods〕

The following points were evaluated about each said Example and the comparative example. The results are shown in Table 1 and Table 2. The samples used for evaluation are the copper base material, copper film thickness, and copper manufacturing conditions sample which were manufactured by the Example and the comparative example in order to compare on unified conditions except the indentation depth evaluation.

(1) pencil hardness

The pencil hardness of the surface of the hard coat layer of the obtained hard coat film was evaluated according to JISK5600-5-4 (1999). That is, five lines were drawn with a 500-g load using the pencil of 2H-4H, and the presence or absence of the flaw of the hard-coat layer after that was visually evaluated, and the following reference | standard evaluated.

<Evaluation Criteria>

Evaluation (circle): Scratches were 0-1.

Evaluation ○: The scratches were 2-3 pieces.

Evaluation x: The scratches were 4-5 pieces.

(2) haze

It measured by the transmission method according to JIS-K-7105 using the haze meter HM-150 type (made by Murakami Color Technical Research Institute).

(3) attachment

The hard-coat layer formation surface and the film surface were overlaid, and it left for 20 minutes under the load of 40 kg / cm <2>, and evaluated.

<Evaluation Criteria>

Evaluation ◎: Not attached.

Evaluation ○: Partially attached.

Evaluation ×: It is completely attached.

(4) the height and convex spacing of the uneven shape

The surface of the hard coat layer manufactured according to the said Example and the comparative example was observed using the non-contact three-dimensional surface shape and roughness measuring instrument NewView 6200 made from ZYGO. An example of the observation screen is shown in FIG. As illustrated in FIG. 4 (arrows in the drawing indicate cutouts), arbitrary five cutouts are determined, and any two convex portions are shown from a drawing (for example, FIG. 5) in which a surface roughness curve is plotted for each part. The height and spacing were obtained. A total of 10 points of data were obtained for each of the heights of the convex portions and the intervals between the convex portions, and the average value was obtained. Moreover, the oblique view plot is shown in FIG. 6 in order to understand the state of the surface asperity shape.

It is preferable that the height of the convex portions is greater than 3 nm and 50 nm or less, and the spacing between the convex portions is 50 nm to 5 m. In addition, convex height and convex space | interval can also be measured with atomic force microscope. Also in that case, each average value is calculated | required from an observation screen by the same method as the above.

(5) indentation depth of the hard coat layer

Using Fischer Instruments Co., Ltd. micro hardness tester (PICODENTOR HM500, ISO14577-1), the measurement sample is prepared for each Example and Comparative Example as follows, and the indentation depth when the indentation load 10mN (μm) ) Was measured.

The curable resin composition for hard-coat layers was suitably diluted with a solvent, and what added the UV initiator 3% of the weight of resin solid content was coated on 40 micrometers TAC (The TAC equivalent of Monica Minolta, KC4UYW) using a Meyer bar, and solvent drying After making it cure, it hardened | cured by UV of about 120mj and the sample film which set the hard-coat layer film thickness to 10-20 micrometers was prepared. The reason why the film thickness is wide is that it is important that the indentation depth of the indenter for the hardness test is about 10% of the coating thickness. To do that.

It is preferable that the surface of a sample for a measurement is flat. Therefore, when it is hard to obtain surface flatness only by resin, you may add 0.1%-3% of a leveling agent of resin weight. In addition, in order to ensure the flatness of the sample for a measurement, the sample film which made the size of 2 cm in width and width | variety on the glass 1 mm or more thick was adhere | attached with instant adhesive (Aron alpha). At this time, even if too much of the alpha alpha affects the flatness, the sample is lightly attached using a minimum amount, and then a flat glass is placed on the hard coat surface to insert the sample film, and a weight of 500 g is placed. It left for time, the glass placed on top was removed, and the sample for a measurement was produced. The final form of the sample for measurement becomes a glass / adhesive layer / TAC / hard coat resin layer.

The sample for a measurement was installed in the test bench of the said microhardness collimator, the indentation load was set to 10 mN, and it measured at least 3 times, and the indentation depth data was calculated | required as the average value.

(6) soap-resistant

The 1N solution of KOH was warmed to 60 ° C, and the sample film was impregnated therein for 2 minutes, and then washed with water sufficiently and dried to perform a saponification process. For the measurement of the cross-talk resistance, it was measured in the AFM mode using SII Nano Technology Co., Ltd. make and scanning probe microscope (SPM) (brand name: high precision large stage unit L-trace).

The saponification-processed measurement sample film was affixed and fixed to the entire surface slide glass with a double-sided tape manufactured by Nichiban Co., Ltd., on a surface of the substrate on which the hard coat was not coated. This was because the measurement was difficult when the sample film had a part that was raised, so that the sample was flattened. The measurement was in tapping mode and the scanning range was 1 μm × 1 μm.

As a result of measuring the saponification process of the sample of the comparative example 1, the part which the hydrophilic microparticles | fine-particles B lost after saponification was seen, and the adhesion prevention property was inferior. On the other hand, when the sample of Example 1 was attached to the same saponification process, the lack of the hydrophilic microparticles | fine-particles B was not observed.

BRIEF DESCRIPTION OF THE DRAWINGS As an example of the cross section of the hard-coat film which concerns on this invention, the figure corresponding to the SEM (100,000 times) photograph which shows the state in which the hydrophilic microparticles B form the aggregate in a hard-coat layer It appears to protrude to the surface, but is wrapped in a matrix component such as resin C).

It is a figure which shows the basic laminated constitution of the hard coat film which concerns on this invention.

It is a schematic diagram of the state which wound the hard-coat film which concerns on this invention in the shape of a long roll.

It is a figure corresponding to an example of the image which observed the surface of the hard coat film which concerns on this invention with the contact three-dimensional surface shape and roughness measuring device.

It is a figure which shows the spectrum analysis obtained by the contact three-dimensional surface shape and roughness measuring instrument which shows the example which measures the height of the convex part formed in the surface of the hard coat film which concerns on this invention, and the space | interval of a convex part.

It is a figure corresponding to the obliquely seen plot which shows the state of the uneven | corrugated shape formed in the surface of the hard cord film concerning this invention.

* Description of the sign *

1: transparent base film

2: hard coat layer

3: hard coat film

Claims (12)

(1) Reactive inorganic fine particles A having an average primary particle diameter of 5 nm or more and 80 nm or less, covering at least a part of the surface with an organic component and having a reactive functional group a introduced by the organic component on the surface; (2) hydrophilic fine particles B having an average primary particle diameter of 100 nm or more and 300 nm or less, (3) a cured reactive matrix containing a binder component C having a reactive functional group c having a crosslinking reactivity with the reactive functional group a of the reactive inorganic fine particles A, Curable resin composition for hard-coat layers containing at least and whose content of the said hydrophilic microparticles | fine-particles B is 0.1 to 5.0 weight% with respect to total solid. The method of claim 1, Curable resin composition for hard-coat layers whose said reactive inorganic fine particles A are reactive silica fine particles. The method according to claim 1 or 2, Curable resin composition for hard-coat layers in which the said reactive inorganic fine particle A has hydrophobicity. The method according to any one of claims 1 to 3, Curable resin composition for hard coat layers whose reactive functional group a of the said reactive inorganic fine particles A and the reactive functional group c of the said binder component C are a polymerizable unsaturated group. The method according to any one of claims 1 to 4, Curable resin composition for hard-coat layers in which the said hydrophilic microparticles | fine-particles B have wettability with respect to alcohol. The method according to any one of claims 1 to 5, Curable resin composition for hard-coat layers whose said binder component C is a compound which has 3 or more of said reactive functional groups c. The method according to any one of claims 1 to 6, Curable resin composition for hard-coat layers in which the said binder component C has hydrophobicity. At least the hard coat layer which consists of hardened | cured material of the curable resin composition for hard-coat layers in any one of Claims 1-7 on a transparent base film, and further laminate | stacks 1 or 2 or more resin layers on it. Hard coat film which may be good. The method of claim 8, The hard coat in which the hydrophilic microparticles | fine-particles B in the said hard-coat layer have the convex part of 50 nm or less height larger than 3 nm on the surface of the said hard-coat layer, and formed the unevenness | corrugation of 50 nm-5 micrometers between convex parts. film. The method of claim 9, When there are a hard coat layer and other laminated resin layers, the hardness of the whole laminated resin layer is represented by the indentation depth of 1.3 micrometers or less, when the indentation load is measured by 10 mN. The method according to any one of claims 8 to 10, The hard coat film whose film thickness of the said hard-coat layer is 1 micrometer or more and 50 micrometers or less. The method according to any one of claims 8 to 11, A hard coat film, wherein the hard coat film is a long roll wound continuously in a continuous band-like state.

Images