KR20100016539A - Anti-dazzling film, anti-dazzling polarizing plate, and image display device - Google Patents

Abstract

This invention provides an anti-dazzling film comprising a transparent support and an anti-dazzling layer having a fine concavoconvex surface provided on the transparent support. The anti-dazzling film satisfies the requirements that the relative scattering light intensity T (20) defined as a relative scattering light intensity when the relative scattering intensity in an anti-dazzling layer side normal direction (12) upon the incidence of light through the transparent support side at an angle of incidence (Φ) (20°) is T (Φ), is 0.0001 to 0.0005%, and the relative scattering light intensity T (30) defined as a relative scattering light intensity for 30° incidence is 0.00004 to 0.00025%.

Description

Anti-glare film, anti-glare polarizing plate and image display device {ANTI-DAZZLING FILM, ANTI-DAZZLING POLARIZING PLATE, AND IMAGE DISPLAY DEVICE}

The present invention relates to an anti-glare (anti-glare) film having a low haze while exhibiting excellent anti-glare performance, and an image display device having the anti-glare film.

The present invention is an anti-glare (anti-glare) film that exhibits excellent anti-glare performance, does not fade, does not cause glare when applied to an image display device, expresses high contrast, and imparts good visibility. An anti-glare polarizing plate provided with an anti-glare film and an image display device.

In an image display device such as a liquid crystal display, a plasma display panel, a cathode ray tube (cathode ray tube: CRT) display, an organic electroluminescent (EL) display, and the like, when external light is reflected on the display surface, visibility is remarkably impaired. In order to prevent such projection of external light, conventionally, the surface of an image display device has been used in televisions, personal computers, which focus on image quality, video cameras and digital cameras used outdoors with strong external light, and mobile phones which display using reflected light. The film layer which prevents projection of external light was provided in the. This film layer is roughly divided into a film consisting of a film subjected to antireflection treatment using interference by an optical multilayer film and a film subjected to an antiglare treatment that scatters incident light by forming fine irregularities on the surface to apply a projection image. . Among these, the former antireflective film needs to form a multilayer film having a uniform optical film thickness, so that the cost is high. On the other hand, since the latter anti-glare film can be produced relatively inexpensively, it is widely used for applications such as large personal computers and monitors.

Such an anti-glare film is conventionally applied by, for example, a method of forming a random unevenness on a sheet by applying a resin solution obtained by dispersing a filler onto a base sheet, adjusting the coating film thickness and exposing the filler to the coating film surface. Is being manufactured. However, the anti-glare film produced by dispersing such a filler is difficult to obtain the unevenness as intended, because the arrangement and shape of the unevenness depend on the dispersed state, the coated state, and the like of the filler in the resin solution. Sufficient anti-glare performance could not be obtained. Moreover, when such a conventional anti-glare film is arrange | positioned on the surface of an image display apparatus, so-called light fading may arise in which the whole display surface becomes white light by scattered light, and a display becomes a dim color.

Moreover, with the recent sharpening of image display apparatuses, the so-called glare phenomenon which the pixel unevenness of the image display apparatus and the surface unevenness | corrugation shape of an anti-glare film interfere with, and a luminance distribution generate | occur | produces as a result and was hard to see easily was easy to generate | occur | produce. In order to eliminate glare, there is an attempt to scatter light by providing a refractive index difference between the binder resin and the dispersing filler, but when such an anti-glare film is applied to an image display device, the luminance at the time of black display is increased by scattered light. As a result, contrast decreased and the visibility was remarkably reduced.

On the other hand, there also exists an attempt to express anti-glare property only by the fine unevenness | corrugation formed in the surface of a transparent resin layer, without containing a filler. For example, Japanese Patent Laid-Open No. 2002-189106 (Patent Document 1) discloses a three-dimensional 10-point average roughness by curing the ionizing radiation curable resin in a state where an ionizing radiation curable resin is sandwiched between an embossed mold and a transparent resin film. The anti-glare film of the form which the average distance of adjacent convex parts on a three-dimensional roughness reference plane respectively forms the fine unevenness which satisfy | fills predetermined value, and provided the ionizing radiation curable resin layer in which the unevenness was formed on the said transparent resin film is disclosed. It is. In this document, it is preferable to form an uneven surface for embossing by using a roller chromium-plated on the surface of iron, preferably by a sand blasting method or a bead shot method. In order to improve the durability at the time of use, it is preferable to use it after surface chromium plating etc. on the surface of the shape in which the unevenness | corrugation was formed in this way, and it is based on the meaning which can aim at hardening and corrosion prevention accordingly. There is also.

In the manufacturing method of such an embossing roll, since blasting and shot are performed on chromium plating with high hardness, unevenness | corrugation is hard to form and it was also difficult to control the shape of the unevenness | corrugation formed precisely. In addition, as described in Japanese Patent Laid-Open No. 2004-29672 (Patent Document 2), chromium plating often has a rough surface depending on the underlying material and its shape, and an uneven image formed by blasting. Since fine cracks formed in chromium plating are formed on the surface, there is a problem that it is difficult to design what unevenness will occur. Moreover, since there exist the minute crack which arises in chromium plating, the scattering characteristic of the finally obtained antiglare film may change in the undesirable direction.

As another document which discloses the manufacturing method of the roll used for manufacture of the film which has an unevenness | corrugation on the surface, For example, Unexamined-Japanese-Patent No. 2004-29240 (Patent Document 3) and Unexamined-Japanese-Patent No. 2004-90187 ( Patent document 4). The former document discloses a method for producing an embossing roll by the bead short method, and the latter document discloses a step of forming a metal plating layer on the surface of the embossing roll, mirror polishing the surface of the metal plating layer, and mirror polishing. Disclosed is a method of producing an embossing roll through a step of performing a blast treatment using a ceramic bead on a surface of a metal plating layer, and a step of peening as necessary.

In this state in which the blasting is applied to the surface of the embossing roll, distribution of the uneven diameter caused by the particle diameter distribution of the blast particles occurs, and it is difficult to control the depth of the concave portion obtained by the blast, There was a problem in obtaining reproducible irregularities having excellent antiglare function.

In addition, Japanese Patent Application Laid-Open No. 2006-53371 (Patent Document 5) according to the applicant's application forms irregularities by hitting fine particles on the surface of the polished metal, and electroless nickel plating is applied thereto to form a mold. By transferring the uneven surface of the metal mold | die to the transparent resin film, it is disclosed to set it as the anti-glare film excellent in anti-glare performance while being low haze.

Moreover, as a document which prescribed | regulated the transmitted scattered light intensity of an anti-glare film, Unexamined-Japanese-Patent No. 2003-248101 (patent document 6) and Unexamined-Japanese-Patent No. 2004-126495 (patent document 7) are mentioned. In the former document, as a film having an anti-glare hard coat layer on a transparent support, the amount of light scattered in a direction of 5 ° with respect to the amount of light I ₀ which is incident on the transparent support side and passes straight through the transmitted light ( I ₅₎ ratio (I ₅ / I ₀₎ is not less than 3.5%, the ratio of the light quantity (I ₂₀₎ which is scattered in 20 ° direction with respect to the energy _{I 0 (I 20 / I 0} ) is less than or equal to room O.1% of An anti-reflective film is disclosed. The latter literature discloses an anti-glare film having a scattering angle of 0.1 ° to 10 ° showing a maximum value of scattered light intensity and a total light transmittance of 70% to 100%. Even with anti-glare films disclosed in these documents, it was difficult to maintain high contrast, particularly when applied to high definition image display devices.

The present invention provides an anti-glare film that exhibits excellent anti-glare performance, prevents the visibility loss due to light fading, and exhibits high contrast without causing glare when disposed on the surface of a high-definition image display device. An object of this invention is to provide an anti-glare polarizing plate and an image display device to which the anti-glare film is applied.

MEANS TO SOLVE THE PROBLEM As a result of earnestly researching in order to solve the said subject, in the anti-glare film in which the glare-proof layer which has a fine uneven | corrugated surface is formed on a transparent support body, it is anti-glare when light is incident at the incident angle of 20 degrees from the transparent support body side. The relative scattered light intensity T (30) in the layer side normal direction represents a specific value, and the relative scattered light intensity T (30) in the antiglare layer side normal direction when light is incident at an incident angle of 30 ° from the transparent support side is a specified value. It was found that the glare was sufficiently prevented and the contrast hardly decreased when applied to the image display device. Furthermore, in this anti-glare film, when light is incident from the anti-glare layer side at an incident angle of 30 °, the reflectance R (30) with a reflection angle of 30 °, the reflectance R (40) with a reflection angle of 40 °, and the reflectance R (50) with a reflection angle of 50 ° are respectively obtained. When the specific value is indicated, it was found to be more effective in addition to effectively preventing light fading while exhibiting excellent anti-glare property. The present invention has been completed on the basis of these findings, with further studies.

<Start of invention>

That is, in the anti-glare film according to the present invention, an anti-glare layer having a fine uneven surface is formed on the transparent support, and the relative scattered light intensity in the direction of the anti-glare layer side normal when light is incident at an incident angle of 20 ° from the transparent support side. T (20) is 0.0001% or more and 0.0005% or less, and the relative scattered light intensity T (30) in the anti-glare layer side normal direction when light is incident on the incident angle of 30 ° from the transparent support side is 0.00004% or more and 0.00025% or less do.

In this anti-glare film, when light is incident from the anti-glare layer side at an incident angle of 30 °, the reflectance R (30) having a reflection angle of 30 ° is 0.05% or more and 2% or less, and the reflectance R (40) having a reflection angle of 40 ° is 0.0001% or more and 0.005. It is% or less, and it is preferable that reflectance R (50) of 50 degrees of reflection angles is 0.00001% or more and 0.0005% or less.

Moreover, it is preferable to make the surface haze at the time of injecting light perpendicular | vertical to this anti-glare film to 0.1% or more and 5% or less, and to make the whole haze 5% or more and 25% or less.

This anti-glare film uses 40 types of optical combs of 0.5 mm, 1.0 mm, and 2.0 mm in width of the dark part and the root, so that the sum of the reflection sharpness measured at the incidence angle of light at 45 ° is 40% or less. Can be.

Moreover, the arithmetic mean height Pa in the cross-sectional curve of the uneven surface which comprises an anti-glare layer is 0.05 micrometer or more and 0.2 micrometer or less, the maximum cross-sectional height Pt is 0.2 micrometer or more and 1 micrometer or less, and this anti-glare film has an average It is preferable that length PSm is 15 micrometers or more and 30 micrometers or less.

The uneven surface constituting the antiglare layer preferably has 50 or more 100 convex portions in an area of 200 μm × 200 μm, and the surface of the convex portion has a peak of the convex portion as its mother point. It is preferable that the average area of the polygon formed when it is made is 100 micrometer <^2> or more and 1,000 micrometer <^2> or less.

It is preferable that the anti-glare layer in this anti-glare film forms surface uneven | corrugated by transfer from the metal mold | die which has an uneven surface. And this anti-glare layer contains 10 weight part-100 weight part of microparticles | fine-particles whose average particle diameters are 5 micrometers or more and 15 micrometers or less with respect to 100 weight part of binder resins, and whose refractive index difference with a binder resin is 0.01 or more and 0.06 or less. In addition, it is preferable that the fine particles are completely embedded in the antiglare layer, and the fine particles do not affect the uneven shape of the surface.

In this antiglare film, a low reflection film can be formed on the uneven surface of the antiglare layer.

The anti-glare film of this invention can be set as an anti-glare polarizing plate in combination with the polarizer which consists of polyvinyl alcohol-type resin. This anti-glare polarizing plate becomes a structure which specifically bonded the transparent support side of the said anti-glare film to the polarizer.

Moreover, the anti-glare film or anti-glare polarizing plate of this invention can be used as an image display apparatus in combination with image display elements, such as a liquid crystal display element and a plasma display panel. Therefore, the image display apparatus which concerns on this invention is equipped with the said anti-glare film or anti-glare polarizing plate, and image display means, and this anti-glare film or anti-glare polarizing plate is arrange | positioned at the visual recognition side of an image display element.

BRIEF DESCRIPTION OF THE DRAWINGS It is a perspective view which shows typically the incidence direction of light and the transmission scattered light intensity measurement direction at the time of obtaining the scattered light intensity observed in the anti-glare layer side normal line by injecting light from the transparent support side of an anti-glare film.

2 is an example of a graph in which relative scattered light intensities (logarithmic scales) measured by changing the incident angle are plotted against the incident angle.

3 is a perspective view schematically showing an incident direction and a reflection direction of light from the antiglare layer side when obtaining a reflectance.

4 is an example of a graph plotting the reflection angle and reflectance (reflectivity is logarithmic scale) of the reflected light with respect to light incident at an angle of 30 ° from the normal of the antiglare film.

5 is a perspective view schematically showing an algorithm for determining convex portions of an antiglare film.

6 is a Voronoi diagram illustrating an example of Voronoi splitting.

It is a cross-sectional schematic diagram which shows the manufacturing method of the metal mold | die for manufacturing an anti-glare film concerning this invention for every process.

It is a cross-sectional schematic diagram which shows the state which grind | polished the surface after chrome plating.

9 is a plan view showing a unit cell of a glare evaluation pattern.

It is a cross-sectional schematic diagram which shows the state of glare evaluation.

It is a graph which shows the transmission scattering profile of the anti-glare film obtained in Examples 1-4.

It is a graph which shows the reflection profile of the anti-glare film obtained in Examples 1-4.

It is a graph which shows the transmission scattering profile of the anti-glare film obtained by the comparative examples 1 and 2. FIG.

14 is a graph showing the reflection profile of the antiglare films obtained in Comparative Examples 1 and 2. FIG.

It is a graph which shows the permeation scattering profile of the anti-glare films obtained in Comparative Examples 3-5.

It is a graph which shows the reflection profile of the anti-glare film obtained by the comparative examples 3-5.

It is a graph which shows the permeation scattering profile of the anti-glare film used in Comparative Examples 6-9.

It is a graph which shows the reflection profile of the anti-glare film used in Comparative Examples 6-9.

<Description of the code>

11... … Antiglare film

12... … Film normals

13... … Incident light direction when measuring the transmitted scattered light intensity

14... … Measurement direction of transmitted scattered light intensity (normal direction)

15... … Incident light direction when measuring reflectance

16... … Specular reflection direction

17... … Arbitrary reflection direction

19... … Face containing incident light direction and film normal

Ø… … Incidence angle when measuring the transmitted scattered light intensity

? … Reflect angle when measuring reflectance

21... … Any point on the antiglare film

22... … Antiglare film surface

23... … Film reference plane

24... … Projection circle to film reference plane of circle centered on any point on antiglare film

26... … Projection point of convex vertex (parent point of Voronoi split)

27... … Voronoi polygon

28... … Voronoi polygons bordering the measured field of view that do not count to the mean

31... … Metal substrate

32... … Copper or nickel plated layer

33... … Polished surface

34... … Concave

35... … Copper plating layer

36a... … Surface blunted by etching blunted concave and convex surfaces

36b... … The surface which blunted the copper bumps formed by bumping the fine particles.

37... … Chrome plated layer

38... … Uneven surface remaining after chrome plating

39... … Flat surface generated when the surface after chrome plating is polished

40... … Unit cell of photomask

41... … Chrome shading pattern of photomask

42... … Opening of the photomask

43.. … Photomask

45... … Light box

46... … Light source

47... … Glass plate

49... … Location of observation of glare

BEST MODE FOR CARRYING OUT THE INVENTION [

EMBODIMENT OF THE INVENTION Hereinafter, preferred embodiment of this invention is described in detail. The anti-glare film of the present invention has an anti-glare layer having a fine uneven surface on the transparent support, and has a relative scattered light intensity T (20) observed in the anti-glare layer-side normal direction when light is incident at an incident angle of 20 ° from the transparent support. Represents a value of 0.0001% or more and 0.0005% or less, and the relative scattered light intensity T (30) observed in the antiglare layer side normal direction when the light is incident at an incident angle of 30 ° from the transparent support side represents a value of 0.00004% or more and 0.00025% or less. will be.

In addition, in order to effectively suppress light fading while exhibiting excellent anti-glare performance, when light is incident from the anti-glare layer side at an incident angle of 30 °, the reflectance R (30) having a reflection angle of 30 ° is 0.05% or more and 2% or less, and has a reflection angle of 40 °. It is preferable that the reflectance R (40) is 0.0001% or more and 0.005% or less, and the reflectance R (50) of 50 degrees of reflection angles is 0.00001% or more and 0.0005% or less.

Relative scattered light intensity

First, the relative scattered light intensities T (20) and T (30) in the direction of the antiglare layer side normal when light is incident from the transparent support side at an incident angle of 20 ° and when light is incident at an incident angle of 30 ° will be described. .

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 schematically illustrates the incident direction of light and the measured direction of transmitted scattered light intensity when light is incident from the transparent support side (the side opposite to the uneven surface) and the scattered light intensity is measured in the antiglare layer side (uneven surface side) normal line direction. It is a perspective view shown by. With reference to this figure, with respect to the light 13 which inject | emitted from the normal line 12 at a certain angle Ø (respective angle) from the transparent support side of the antiglare film 11 in the normal direction 12 on the side of the antiglare layer. The intensity of the transmitted scattered light 14 is measured, and the value obtained by dividing the transmitted scattered light intensity by the light intensity of the light source is taken as the relative scattered light intensity T (Ø). That is, when the incident light 13 is incident on the transparent support side of the antiglare film 11 at an angle of 20 ° from the normal, the intensity of the emitted light 14 observed in the antiglare layer side normal direction 12 is determined by the light intensity of the light source. When the value divided by is T (20) and the incident light 13 is incident at an angle of 30 ° from the normal line 12 on the transparent support side of the antiglare film 11, the emission observed in the antiglare layer side normal direction 12 The value of the light 14 divided by the light intensity of the light source is T (30).

When the relative scattered light intensity T (20) at 20 ° incidence exceeds 0.0005%, when the anti-glare film is applied to the image display device, the luminance at the time of black display is increased due to the scattered light, and the contrast is lowered. , Not preferred. In addition, when the relative scattered light intensity T 20 at 20 ° incidence is less than 0.0001%, glare occurs when the scattering effect is low and is applied to a high definition image display device, which is also undesirable. Similarly, even when the relative scattered light intensity T (30) at 30 ° incidence exceeds 0.00025%, when the antiglare film is applied to the image display device, the scattered light increases the luminance at the time of black display, and the contrast decreases. It is not preferable because it is made. In addition, even when the relative scattered light intensity T (30) at 30 ° incidence is less than 0.00004%, it is not preferable because the scattering effect is low and glare occurs when applied to a high definition image display device. In particular, when the anti-glare film is applied to a liquid crystal display which is not a self-luminous type, the relative scattered light intensity T (20) and T (30) are the present invention because the effect of increasing the luminance due to scattering caused by light leakage during black display is large. If it exceeds the regulation, the contrast is significantly lowered and the visibility is impaired.

As the documents mentioned so far about the transmitted scattered light intensity, for example, Patent Document 6 (Japanese Laid-Open Patent Publication No. 2003-248101) and Patent Document 7 (Japanese Patent Laid-Open Publication No. 2004-126495), and the like, are mentioned. Also, unlike the scattering characteristics defined in the present invention, it cannot be said that it is necessarily sufficient to achieve high contrast and suppress glare when applied to an image display device.

FIG. 2 is an example of a graph in which the relative scattered light intensity (logarithmic scale) measured by changing the incident angle Ø from the transparent support side of the antiglare film 11 in FIG. 1 is plotted against the incident angle Ø.

A graph showing the relationship between the incident angle and the relative scattered light intensity or the relative scattered light intensity for each incident angle read therefrom may be referred to as a transmission scattering profile. As shown in this graph, the relative scattered light intensity shows a peak at the incident angle of 0 °, and the scattered light intensity tends to decrease as the angle from the normal line direction of the incident light 13 is shifted. In addition, the positive (+) and the negative (-) angles of incidence are inclined to the inclination of the incident light in the plane 19 including the direction 13 of the incident light and the normal 12 around the normal direction (0 °). It is decided by. Therefore, it is common for the transmission scattering profile to appear symmetrically around the incident angle of 0 °. In the example of the transmission scattering profile shown in FIG. 2, the relative scattered light intensity T (0) at 0 ° incidence shows a peak at about 30%, and the relative scattered light intensity T (20) at 20 ° incidence is about 0.0002%, 30 The relative scattered light intensity T (30) at the time of incidence is about 0.00004%.

In measuring the relative scattered light intensity of the antiglare film, it is necessary to accurately measure the relative scattered light intensity of 0.001% or less. Therefore, the use of a detector with a wide dynamic range is effective. As such a detector, for example, a commercially available optical power meter or the like can be used, and the measurement can be performed using a variable photometer in which an opening is provided in front of the detector of the optical power meter and the angle of viewing the antiglare film is 2 °. .

Visible light of 380 nm to 780 nm can be used for the incident light, and as a light source for measurement, one obtained by collimating light from a light source such as a halogen lamp may be used. Also good. Moreover, in order to prevent curvature of a film, it is preferable to use for an optically transparent adhesive and to provide it for a measurement, after bonding to a glass substrate so that an uneven surface may become a surface.

[Reflectivity at 30 ° incidence]

Next, the reflectance for each angle when light is incident at the incident angle of 30 ° from the antiglare layer side will be described. 3 is a perspective view schematically showing an incident direction and a reflection direction of light from an antiglare layer side with respect to an antiglare film when a reflectance is obtained. With reference to this figure, with respect to the incident light 15 incident on the antiglare layer side of the antiglare film 11 at an angle of 30 ° from the normal line 12, the reflected light in the direction of the reflection angle of 30 °, that is, the specular reflection direction 16 Let reflectance (ie, specular reflectance) be R (30). In addition, the reflected light at arbitrary reflection angles (theta) is denoted by reference numeral 17, and the directions 16 and 17 of the reflected light when measuring the reflectance are planes including the direction 15 and the normal line 12 of the incident light. (19) It is in. The reflectance in the direction of the reflection angle of 40 ° is set to R (40), and the reflectance in the direction of the reflection angle of 50 degrees is set to R (50).

In the anti-glare film of the present invention, it is preferable that the reflectance in the direction of the reflection angle 30 °, that is, the specular reflectance R (30), is 0.05% or more and 2% or less with respect to the incident light having an incident angle of 30 °. The reflectance R (40) in the direction of the reflection angle of 40 ° is preferably 0.0001% or more and 0.005% or less, and the reflectance R (50) in the direction of the reflection angle 50 ° of 0.00001% or more and 0.0005% or less.

When the specular reflectance R (30) exceeds 2%, sufficient anti-glare function cannot be obtained, and the visibility decreases. On the other hand, even if the specular reflectance R (30) is too small, light fading tends to occur, so it is preferably 0.05% or more. The reflectance R (30) is more preferably 1.5% or less, particularly 0.7% or less. Moreover, when R (40) exceeds 0.005% or R (50) exceeds 0.0005%, light fading will generate | occur | produce in an anti-glare film, and visibility will fall. That is, for example, even when black is displayed on the display surface in the state where the antiglare film is provided on the front surface of the display device, there is a tendency that light fading occurs by collecting light from the surroundings and causing the display surface to become white as a whole. Therefore, it is preferable not to make R (40) and R (50) too big. On the other hand, even if the reflectance at these angles is too small, sufficient anti-glare property is not exhibited, so that R (40) is generally preferably 0.0001% or more, and R (50) is generally preferably 0.00001% or more. R (50) is more preferably 0.0001% or less.

FIG. 4 shows the reflection angle and the reflectance (reflectivity is logarithmic scale) of the reflected light 17 with respect to the incident light 15 incident on the antiglare layer side of the antiglare film 11 in FIG. 3 at an angle of 30 ° from the normal 12. It is an example of a plotted graph. A graph showing the relationship between the reflection angle and the reflectance or the reflectance for each reflection angle read therefrom may be referred to as a reflection profile. As shown in this graph, the specular reflectance R (30) is a peak of the reflectance with respect to the incident light 15 incident at 30 degrees, and the reflectance tends to decrease as the angle shifts from the specular reflection direction. In the example of the reflection profile shown in FIG. 4, the specular reflectance R (30) is about 0.2%, R (40) is about 0.0004%, and R (50) is about 0.00005%.

According to the investigation by the present inventors, most of the anti-glare film currently on the market is a type which disperse | distributed the filler, and in such an anti-glare film, the relative scattered light intensity T (20) at 20 degrees incidence is 0.0001% or more and 0.0005% The relative scattered light intensity T (30) at the time of 30 ° incidence was no more than 0.00004% and no less than 0.00025%. In addition to the transmission scattering characteristics, the reflectance R (30) is 0.05% or more and 2% or less, the reflectance R (40) having a reflection angle of 40 ° is 0.0001% or more and 0.005% or less, and the reflectance R (50) having a reflection angle of 50 ° There was no thing which became 0.00001% or more and 0.0005% or less. As a result, there was no glare-proof anti-glare film which showed no glare, showed high contrast, and showed sufficient anti-glare performance. On the other hand, while the anti-glare film prescribed | regulated by this invention showed sufficient anti-glare performance, it turned out that light fading is suppressed and it is excellent.

In measuring the reflectance of an anti-glare film, it is necessary to measure the reflectance of 0.001% or less with high precision similarly to a relative scattered light intensity. Therefore, the use of a detector with a wide dynamic range is effective. As such a detector, a commercially available optical power meter or the like can be used, for example, an opening is provided in front of the detector of the optical power meter, and measurement can be performed using a variable photometer such that the angle of viewing the antiglare film is 2 °. . As incident light, visible light of 380 nm to 780 nm can be used, and as a light source for measurement, one obtained by collimating light from a light source such as a halogen lamp may be used, and one having a high degree of parallelism using a monochromatic light source such as a laser. You may also do it. In the case of a transparent and transparent antiglare film, since the reflection from the back of the antiglare film may affect the measured value, for example, a black acrylic resin plate may be used as an adhesive or water or glycerin. It is preferable to make it possible to measure only the reflectance of the outermost surface of an anti-glare film by optical close contact using a liquid.

[Haze]

In addition, the anti-glare film of the present invention has a surface haze of 0.1% or more and 5% or less for vertical incident light in order to prevent light fading and effectively suppress glare when applied to a high-definition image display device. It is preferable that they are 5% or more and 25% or less. The whole haze of an anti-glare film can be measured based on the method shown to JISK7136. After dividing the surface haze and the internal haze, after measuring the total haze, a transparent film having almost zero haze on the uneven surface may be adhered with glycerin to measure the internal haze, and the surface haze may be obtained according to the following equation.

Surface haze = total haze-internal haze

Since the haze value measured in the state which adhered the transparent film whose haze was almost 0 to the uneven | corrugated surface of an anti-glare film hardly loses the surface haze resulting from original uneven | corrugated, it may be considered that it shows an internal haze actually. As a transparent film with a haze of almost zero, if a haze is small, it will not specifically limit, For example, a triacetyl cellulose film etc. may be used.

When the surface haze is higher than 5%, light fading tends to occur, and when the surface haze is lower than 0.1%, it is not preferable because it does not exhibit sufficient anti-glare property. In addition, it is preferable that all the haze is 5% or more, since it can effectively eliminate glare. However, if the total haze exceeds 25%, it is not preferable because the screen becomes dark as a result and the visibility is impaired when applied to the image display device.

[Reflection Sharpness]

In the anti-glare film of the present invention, it is also preferable that the sum of the reflection clarity measured at an incident angle of 45 ° of light using three types of optical combs of 0.5 mm, 1.0 mm, and 2.0 mm in width of the dark portion and the roll is 40% or less. Reflection sharpness is measured by the method prescribed | regulated to JISK7105. In this standard, as an optical comb used for measuring image sharpness, four types of the ratio of the width | variety of a dark part and a wrist are 1: 1 and the width | variety is 0.125 mm, 0.5 mm, 1.0 mm, and 2.0 mm. Among these, when the optical comb of 0.125 mm width is used, since the error of the measured value becomes large in the anti-glare film prescribed | regulated by this invention, the measured value at the time of using the optical comb of width 0.125 mm shall not add to sum, The sum of image clarity measured using three types of optical combs having a width of 0.5 mm, 1.0 mm and 2.0 mm will be referred to as reflection clarity. The maximum value of the reflection sharpness in the case of following this definition is 300%. When the reflection sharpness according to this definition exceeds 40%, an image such as a light source is clearly projected, which is not preferable because the anti-glare property is inferior.

However, when the reflection sharpness becomes 40% or less, it becomes difficult to compare the superiority of anti-glare property only from reflection sharpness. If the reflection clarity according to the above definition is 40% or less, the respective reflection clarities using optical combs of 0.5 mm, 1.0 mm and 2.0 mm in width are only about 10%, and the reflection sharpness due to measurement error ( deflection) cannot be ignored.

Therefore, in the present invention, by defining the relative scattered light intensity for the anti-glare film having a reflection clarity of 40% or less, preferably by combining it with the reflectance at the incidence of 30 °, the anti-glare performance of the anti-glare film can be suitably evaluated as an index. Doing.

[Surface shape]

Next, the surface shape in the anti-glare layer uneven surface of an anti-glare film is demonstrated. The antiglare film of the present invention preferably satisfies the following one or more requirements as the uneven surface shape factor in order to more effectively suppress the glare and to make the texture uniform and uniform when the appearance is visually observed. Do.

(1) In the cross-sectional curve of the uneven surface constituting the antiglare layer, the arithmetic mean height Pa is 0.05 µm or more and 0.20 µm or less, the maximum cross-sectional height Pt is 0.2 µm or more and 1.0 µm or less, and the average length PSm Is 15 µm or more and 30 µm or less,

(2) the uneven surface constituting the antiglare layer has 50 or more and 100 or less convex portions in an area of 200 µm x 200 µm,

(3) The average area of the polygons formed when the surface is divided by Voronoi with the peak of the convex portion of the uneven surface constituting the antiglare layer is 100 µm ² or more and 1,000 µm ² or less.

First, arithmetic mean height Pa, maximum cross-sectional height Pt, and average length PSm in the cross-sectional curve of the uneven surface constituting the antiglare layer will be described. These values are prescribed | regulated to JIS B 0601 (= ISO 4287), and an arithmetic mean height Pa is the same as a value called center line average roughness.

When the arithmetic mean height Pa in the cross-sectional curve of the uneven surface is less than 0.05 µm, the surface of the antiglare film is almost flat, and it is not preferable because it does not exhibit sufficient antiglare performance. In addition, when the arithmetic mean height Pa is larger than 0.2 µm, the surface shape becomes rough, light fading occurs, and the texture when the appearance is visually observed becomes rough, which is also undesirable. If the maximum cross-sectional height Pt in the cross-sectional curve of the uneven surface is less than 0.2 µm, the surface of the anti-glare film is also almost flat, which is not preferable because it does not exhibit sufficient anti-glare performance.

In addition, when the maximum cross-sectional height Pt is larger than 1 µm, the surface shape is also rough, and problems such as light fading and texture deterioration occur, which is not preferable. When the average length PSm in the cross-sectional curve of the uneven surface is less than 15 m, sufficient anti-glare property cannot be obtained, which is not preferable. It is thought that this is because if the average length PSm is too small, the peaks of the unevenness (the surface tilt angle thereof is considered to be almost 0 °) are close to each other, and thus they are imaged when visually observed. Moreover, when average length PSm is larger than 20 micrometers, since the texture when the external appearance is observed visually becomes rough, it is also unpreferable.

The arithmetic mean height (Pa), the maximum cross-sectional height (Pt), and the average length (PSm) in the cross-sectional curve of the uneven surface can be measured using a commercially available general contact surface roughness measuring system in accordance with JIS B 0601. . Moreover, it is also possible to measure a surface shape with apparatuses, such as a confocal microscope, an interference microscope, and an atomic force microscope, and to calculate | require it by calculation from the three-dimensional information of the surface shape. In addition, when calculating from three-dimensional information, in order to ensure a sufficient reference length, it is preferable to measure three or more points | pieces of 200 micrometers x 200 micrometers or more, and to make it the measured value with the average value.

Next, the number of the convex parts observed on the uneven surface is demonstrated. When the number of convex portions on the uneven surface is small, when used in combination with a high-definition image display device, glare occurs due to interference with pixels, the image becomes difficult to see, and the texture is also deteriorated, which is not preferable. In addition, when the number of the convex parts becomes too large, the inclination angle of the surface asperity shape becomes a steep slope as a result, and light fading tends to occur. Therefore, on the uneven surface, it is preferable to have 50 or more and 100 or less convex portions in the region of 200 µm x 200 µm.

In obtaining the number of the convex parts in the uneven surface of an anti-glare film, surface shape is measured by apparatuses, such as a confocal microscope, an interference microscope, and atomic force microscope (AFM), and the three-dimensional coordinate of each point of an anti-glare film surface After obtaining the value, the convex portion is determined by the algorithm shown below, and the number is counted. That is, when paying attention to any point on the surface of the antiglare film, there is no point higher than the point of focus around the point, and the elevation at the uneven surface of the point is different from the height of the highest point of the uneven surface. When it is higher than the middle of the elevation of the lowest point, the point is called the peak of the convex portion, and the number of the peaks of the convex portion thus obtained is counted to be the number of the convex portions.

More specifically, as shown in FIG. 5, 2 micrometers-5 radius of attention are paid to arbitrary points 21 of the anti-glare film surface, and are parallel to the anti-glare film reference surface 23 centering on the point 21. When a circle of μm is drawn, there is no point on the antiglare film surface 22 included in the projection surface 24 of the circle, the height of which is higher than the point 21 of interest, and the uneven surface of the point. When the altitude is higher than the middle of the elevation of the highest point of the uneven surface and the elevation of the lowest point, it is determined that the point 21 is the apex of the convex portion, and the number of the convex portions is obtained. In this case, the radius of the circle 24 is not required to count fine irregularities on the sample surface and is required to be of a size that does not include a plurality of convex portions, and is preferably about 3 μm. In measurement, in order to reduce an error, it is preferable to measure the area | region of 200 micrometers x 200 micrometers or more, and to make it a measured value with the average value.

In the case of using a confocal microscope, the magnification of the objective lens is about 50 times, and it is preferable to reduce the resolution and measure it. This is because when the measurement is performed at a high resolution, fine irregularities on the surface of the sample are measured to cause a disturbance in the count of the convex portion. In addition, when the objective lens is set to a low magnification, the resolution in the height direction is also lowered, so that in the case of a sample having few unevenness, it may be difficult to measure the surface shape. In this case, after measuring with a high-magnification objective lens, a lowpass filter is applied to the obtained data to drop a component having a high spatial frequency, so that the fine roughness observed on the uneven surface is not seen, and then the convex portion You may count the number.

Next, the average area of the polygon formed when the surface is divided by Voronoi with the convex apex of the uneven surface as a mother point will be described. First, the Voronoi segmentation is described. When a number of points (called a parent point) are arranged on a plane, a drawing is made by dividing the plane according to which parent point an arbitrary point in the plane is closest to. It is called a noido, and the division is called a Voronoi division. 6 shows an example in which the surface of the antiglare film has the peak of the convex portion as its mother point, and the surface is divided by Voronoi, but the rectangular points 26 and 26 are the mother points, and each polygon includes one mother point. Although (27, 27) is an area | region formed by Voronoi division | segmentation, it is called a Voronoi area | region or a Voronoi polygon, but is called a Voronoi polygon hereafter. In this figure, the surrounding lightly painted portions 28 and 28 will be described later. In Voronoiido, the number of parent points and the number of Voronoi regions coincide.

In this way, it is preferable that the average area of the Voronoi polygon formed when the Voronoi dividing is made with the vertex of a convex part as a parent point is 100 micrometer <^2> or more and 1,000 micrometer <^2> or less. When the average area at this time is less than 100 micrometer <^2> , since the inclination angle of the anti-glare film surface becomes steep inclination and light fading tends to occur as a result, it is unpreferable. In addition, when the average area of the Voronoi polygon is larger than 1,000 µm ² , the uneven surface shape becomes rough, glare is likely to occur, and the texture is also deteriorated, which is not preferable.

In obtaining the average area of the Voronoi polygon obtained by performing Voronoi segmentation with the convex apex on the surface of an antiglare film as a parent point, it is surface shape by apparatuses, such as a confocal microscope, an interference microscope, and an atomic force microscope (AFM). After the measurement, the three-dimensional coordinate value of each point on the anti-glare film surface is calculated, and the Voronoi segmentation is performed by the algorithm shown below to obtain the average area of the Voronoi polygon. That is, first, the vertices of the convex portions on the surface of the antiglare film are obtained according to the algorithm described with reference to FIG. 5, and then the vertices of the convex portions are projected onto the antiglare film reference plane. Subsequently, all three-dimensional coordinates obtained by surface shape measurement are projected on the reference plane, and the Voronoi segmentation is performed by assigning all of these projected points to the nearest parent point, thereby obtaining the area of the polygon obtained by dividing. Find the average area of a polygon. In the measurement, in order to reduce the error, the Voronoi polygons in contact with the boundary of the measurement field of view are calculated as the number of the convex portions in the previous section, but are not calculated when calculating the average area. In addition, in order to reduce a measurement error, it is preferable to measure three or more areas of 200 micrometers x 200 micrometers or more, and to set it as a measured value with the average value.

As described first, FIG. 6 is a Voronoi diagram illustrating an example of the Voronoi segmentation using the convex apex of the antiglare film as a parent point. Many parent points 26 and 26 are the convex apex of an anti-glare film, and one Voronoi polygon 27 is assigned with respect to one mother point 26 by Voronoi division | segmentation. In this figure, the Voronoi polygons 28 and 28 that are in light contact with the boundary of the visual field are not counted in calculating the average area as described above. In addition, in this figure, although a leader line and a code | symbol are attached | subjected only to a part of a parent point and a Voronoi polygon, it is easily understood from the above description and this figure that many parent points and Voronoi polygon exist.

[Transparent Support and Anti-glare Layer]

The anti-glare film of this invention forms the anti-glare layer which has a fine uneven surface on the transparent support body. A transparent support body supports the anti-glare layer which has an uneven surface, and can be comprised by the resin film which is substantially optically transparent. As an example of a transparent support body, the solvent cast film, the extruded film, etc. which consist of thermoplastic resins, such as a tricyclic cellulose, polyethylene terephthalate, polymethyl methacrylate, polycarbonate, and an amorphous cyclic polyolefin which uses a norbornene-type compound as a monomer, are mentioned. have.

The anti-glare layer is a layer provided with surface irregularities that satisfy the transmission scattering characteristics as described above, and is formed on the transparent support. This anti-glare layer is a method of forming random irregularities on a transparent support by applying a resin solution obtained by dispersing a filler which has been widely used on a transparent support, adjusting the coating film thickness and exposing the filler to the coating film surface. Although it can also manufacture, it is preferable that the surface unevenness | corrugation of an anti-glare layer is formed by the transfer from the metal mold | die which has an uneven surface. And it is preferable that this anti-glare layer contains 10 weight part-100 weight part of microparticles | fine-particles whose average particle diameters are 5 micrometers or more and 15 micrometers or less with respect to 100 weight part of binder resins, and whose refractive index difference with a binder resin is 0.01 or more and 0.06 or less. In addition, it is preferable that the fine particles are completely embedded in the antiglare layer, and the fine particles do not affect the uneven surface shape. In this way, by independently controlling the surface fine concavo-convex shape and the internal scattering of the anti-glare film, it is possible to divide and control the surface fine concavo-convex shape of the antiglare film mainly determining the reflection characteristic and the composition of the antiglare layer mainly determining the transmission characteristic. As a result, it becomes possible to achieve the said optical characteristic easily. The formation of such an antiglare layer will be described later in detail.

Although the anti-glare film of this invention shows sufficient anti-glare function even in the state which does not have a low reflection film in the outermost surface, ie, the uneven surface side, it can also be used in the state which attached the low reflection film to the outermost surface. The low reflection film can be formed on the antiglare layer by providing a layer of low refractive index material having a lower refractive index than that. As such a low refractive index material, specifically, inorganic material fine particles such as lithium fluoride (LiF), magnesium fluoride (MgF ₂ ), aluminum fluoride (AlF ₃ ), cryolite (3NaF.AlF ₃ or Na ₃ AlF ₆ ), And inorganic low reflection materials contained in acrylic resins, epoxy resins, and the like, and organic low reflection materials such as fluorine or silicon organic compounds, thermoplastic resins, thermosetting resins, and ultraviolet curable resins.

[Method for Producing Mold for Producing Anti-glare Film]

Next, the method which can manufacture the anti-glare film concerning this invention suitably, and the manufacturing method of the metal mold | die with which the unevenness | corrugation was formed in the surface for obtaining this anti-glare film are demonstrated. The anti-glare film of this invention uses the metal mold | die with which the unevenness | corrugation was formed in the predetermined shape, and transfers the uneven surface of the metal mold | die to the transparent resin film, and then, according to the method of peeling off the transparent resin film with which the uneven surface was transferred, from the metal mold | die, It is advantageously produced. More specifically, the surface of the metal is subjected to copper plating or nickel plating, and after the plating surface is polished, the surface is bumped with fine particles to form unevenness, and then subjected to a process of blunting the uneven shape. The uneven surface is subjected to chromium plating to form a mold, and the uneven surface of the mold is transferred to a resin coated on a transparent support, and then the resin having the uneven transfer transferred is produced according to the method of peeling from the mold for each transparent support. do. In this method, in order to obtain a metal mold having irregularities, copper plating or nickel plating is applied to the surface of the metal substrate, and after the plating surface is polished, fine particles are bumped against the polishing surface to form irregularities. After the dulling process is performed, the uneven surface is subjected to chromium plating to obtain a mold.

First, copper plating or nickel plating is given to the surface of the metal base material which bumps microparticles | fine-particles and forms an unevenness | corrugation and forms a chromium plating layer. Thus, by performing copper plating or nickel plating on the surface of the metal which comprises a metal mold | die, the adhesiveness and glossiness of chromium plating in a subsequent process can be improved. When chromium plating is performed on the surface of iron or the like, or when chromium plating is performed again after the unevenness is formed on the surface of the chromium plating by a sand blasting method or a bead short method, as described in the background art, the surface This roughness tends to be rough and fine cracks may occur, which may adversely affect the shape of the antiglare film. In contrast, it has been found that such problems are eliminated by applying copper plating or nickel plating on the surface. This is because copper plating and nickel plating have a high coating property and a strong smoothing action, and thus form a flat and glossy surface by embedding minute irregularities and cavities of the metal substrate. By the characteristics of these copper plating and nickel plating, the roughness of the chromium plating surface considered to be caused by the minute unevenness | corrugation and the cavity which existed in the metal base material is eliminated, and it is minute from the height of the coating property of copper plating and nickel plating. It is considered that the occurrence of cracks is reduced.

The copper or nickel herein may be a pure metal, but in addition, an alloy mainly composed of copper or an alloy mainly composed of nickel may be used. Accordingly, copper as used herein is meant to include copper and copper alloys, and nickel is also meant to include nickel and nickel alloys. Copper plating and nickel plating may be performed by electrolytic plating or electroless plating, respectively, but electrolytic plating is usually employed.

As a metal suitable for forming a metal mold | die, aluminum and iron etc. are mentioned from a cost viewpoint. Moreover, lightweight aluminum is more preferable from the convenience of handling. The aluminum and the railroad may be pure metals, respectively, but may be an alloy mainly composed of aluminum or iron. The surface of the metal substrate is subjected to copper plating or nickel plating, and the surface is polished to obtain a smoother and more polished surface, and then fine particles are bumped on the surface to form fine irregularities, and the irregularities are blunted. After carrying out the processing to be performed, chromium plating is further applied thereto to form a mold.

When carrying out copper plating or nickel plating, if the plating layer is too thin, since the influence of the underlying metal cannot be excluded, the thickness thereof is preferably 10 µm or more. The upper limit of the thickness of the plating layer is not critical, but from a relationship with cost or the like, it is generally sufficient to be about 500 µm.

The shape of the metal mold may be a flat metal plate or a cylindrical or cylindrical metal roll. When a metal mold is manufactured using a metal roll, an anti-glare film can be manufactured in a continuous roll shape.

7 is a cross-sectional view schematically showing a step up to obtaining a mold by taking a case of using a flat plate as an example. FIG. 7A shows a cross section of the substrate after copper plating or nickel plating and mirror polishing, and a plating layer 32 is formed on the surface of the metal substrate 31, and the surface thereof is the polishing surface 33. It is. Unevenness | corrugation is formed by hitting microparticles | fine-particles on the surface of the plating layer 32 after such mirror polishing. FIG. 7B is a schematic cross-sectional view of the substrate 31 after striking the fine particles, and fine particles 34 having a partial spherical shape are formed when the fine particles collide with each other.

FIG. 7C is a schematic cross-sectional view of the base material 31 after the processing for blunting the uneven shape on the surface where the unevenness by the fine particles is formed in this way, and (C1) shows the state blunted by the etching treatment, And (C2) has shown the state dulled by copper plating, respectively. In addition, in (C1), the state of the partial spherical concave surface corresponding to (B) before dulling by etching is shown by the broken line. In the example employ | adopting the etching process of (C1), the concave surface 34 and acute protrusion shown in (B) are shaved by etching, and the shape 36a in which the sharp protrusion on the partial spherical surface was blunted is formed. On the other hand, in the example employing copper plating of (C2), the copper plating layer 35 is formed on the concave surface 34 shown in (B), whereby the shape 36b in which the acute projection on the partial spherical surface is blunted is Formed.

Thereafter, chromium plating is performed to further blunt the surface irregularities. FIG. 7D is a schematic cross-sectional view after chromium plating, in which (D1) is chromium plating on uneven surface 36a blunted by etching shown in (C1), and (D2) is ( Chromium plating was performed on the copper plating layer 35 shown to C2).

In the example which employs the etching process from (C1) to (D1), the chromium plating layer 37 is formed on the surface 36a of the state dulled by the etching shown to (C1), and the surface 38 is Compared to the uneven surface 36a of (C1), the surface is further blunted by chromium plating, that is, the uneven shape is relaxed. In addition, in the example which employ | adopts copper plating from (C2) to (D2), the copper plating layer 35 is formed on the fine concave surface formed in the copper or nickel plating layer 32 on the base material 31, and on it The chromium plating layer 37 is formed, and the surface 38 is in a state that is more dull than the uneven surface 36b of (C2), in other words, the uneven shape is relaxed by chrome plating. Thus, after bumping microparticles | fine-particles to the surface of the copper or nickel plating layer 32, and forming an uneven | corrugated surface, chromium plating is performed to the surface 36 (36a or 36b) which performed the process which blunted the uneven | corrugated shape, It is possible to obtain a mold having substantially no flat portion. Moreover, such a metal mold | die is suitable for obtaining the anti-glare film which shows preferable optical characteristic.

Although the fine particle collides with the plating layer which consists of copper or nickel on a base material in the state in which the surface was polished, it is preferable to grind especially in the state near a mirror surface. This is because a metal plate or a metal roll serving as a base material is often subjected to machining such as cutting or grinding in order to achieve a desired precision, and thus a processed texture remains on the surface of the base material.

Even in the state of copper plating or nickel plating, these processed textures may remain, and the surface is not completely smoothed in the plated state. In a state in which deep processed textures and the like remain, even when the fine particles collide with each other to deform the surface of the substrate, unevennesses such as processed textures may be deeper than unevenness formed by the fine particles, and the influence of the processed textures may remain.

When manufacturing an anti-glare film using such a metal mold | die, it may have an unexpected effect on an optical characteristic.

There is no particular limitation on the method of polishing the substrate surface subjected to the plating, and both mechanical polishing, electrolytic polishing and chemical polishing can be used. As the mechanical polishing method, a super finishing method, a lapping, a fluid polishing method, a buff polishing method, and the like are exemplified. The surface roughness after grinding | polishing is represented by center line average roughness Ra, and it is preferable that it is 0.5 micrometer or less, More preferably, it is 0.1 micrometer or less. If Ra is too large, it is not preferable because the surface roughness before deformation may remain even if the surface of the metal is deformed by hitting the fine particles. The lower limit of Ra is not particularly limited, and since there is a limitation in terms of processing time and processing cost, there is no need to specify it in particular.

As a method of striking the fine particles to the surface on which the plating of the substrate is applied, a spray processing method is suitably used. The spray processing method includes a sand blasting method, a shot blasting method, a liquid honing method and the like. As the particles to be used for these processing, a shape closer to a spherical shape is preferable to a shape having a sharp angle, and particles of a hard material that are likely to be broken during processing and that sharp angles do not come out are preferable. As the particles satisfying these conditions, in the ceramic particles, spherical zirconia beads and alumina beads are preferably used. Moreover, in metal particle | grains, the bead made from steel or stainless steel is preferable. Moreover, you may use the particle which carried the particle | grains of ceramics and a metal in the resin binder.

As microparticles | fine-particles which hit the surface in which the plating of the base material was performed, it is preferable to use the thing whose average particle diameter is 10 micrometers-150 micrometers, especially spherical microparticles | fine-particles, and, thereby, the anti-glare film which shows the outstanding anti-glare performance can be produced. When the average particle diameter of microparticles | fine-particles is smaller than 10 micrometers, it becomes difficult to form sufficient unevenness | corrugation on the surface in which plating was performed, and it becomes difficult to obtain sufficient anti-glare performance. On the other hand, when the average particle diameter of microparticles | fine-particles is larger than 150 micrometers, surface unevenness | corrugation will become rough, a glare will arise and a texture will fall easily. Here, when processing using the microparticles | fine-particles whose average particle diameter is 15 micrometers or less, it is preferable to employ the wet blasting method which disperse | distributes to a suitable dispersion medium and processes so that particle | grains may not aggregate by static electricity or the like.

In addition, the pressure at the time of hitting the fine particles, the amount of the fine particles used, the distance from the nozzle for injecting the fine particles to the metal surface also affect the uneven shape after processing, and furthermore, the surface shape of the antiglare film. From a gauge pressure of about MPa to 0.4 MPa, an amount of particles of about 4 g to 12 g per cm 2 of surface area of the metal to be treated, and a distance of about 200 mm to 600 mm from the nozzle for injecting the particles to the metal surface What is necessary is just to select suitably according to the kind of particle | grains, particle diameter, a kind of metal, the shape of the nozzle which injects microparticles, a desired uneven | corrugated shape, etc.

As for the uneven | corrugated shape formed by striking microparticles | fine-particles on the surface in which the base material was plated, the arithmetic mean height Pa in a cross section curve is 0.1 micrometer or more and 1 micrometer or less, and the arithmetic mean height Pa and average length in the cross section curve are It is preferable that ratio (Pa / PSm) of (PSm) is 0.02 or more and 0.1 or less. If the arithmetic mean height (Pa) is less than 0.1 µm or the ratio (Pa / PSm) is less than 0.02, the uneven surface becomes almost flat when the uneven surface is blunted before chrome plating. It is difficult to obtain a mold having a desired surface shape. In addition, when arithmetic mean height Pa is larger than 1 micrometer or ratio Pa / PSm is larger than 0.1, the process which blunts the uneven shape before chrome plating process must be performed on strong conditions, and the surface shape It is easy to control.

In this way, a process of blunting the uneven shape is applied to the base material on which the unevenness is formed on the surface of copper plating or nickel plating. As a process to blunt uneven | corrugated shape, etching process or copper plating is preferable as demonstrated previously with reference to FIG.7 (C) and (D). By performing an etching process, the uneven | sharpened part of the uneven | corrugated shape which produced the particle | grains hitting the particle | grains disappears. Thereby, the optical characteristic of the anti-glare film produced when using as a metal mold | die changes to a preferable direction. Moreover, since copper plating has a strong smoothing effect, the effect of blunting the uneven shape is stronger than that of chromium plating. Thereby, the optical characteristic of the anti-glare film produced when using as a metal mold | die changes to a preferable direction.

The etching treatment is usually carried out by etching the surface using an aqueous ferric chloride (FeCl ₃ ) solution, a cupric chloride (CuCl ₂ ) solution, an alkaline etching solution (Cu (NH ₃ ) ₄ Cl ₂ ), or the like, but with hydrochloric acid. Strong acids such as sulfuric acid and sulfuric acid may be used, or reverse electrolytic etching may be used by applying a potential opposite to that of electrolytic plating. Since the blunt state of the unevenness after the etching treatment is different depending on the size and depth of the unevenness obtained by the type of the base metal, the blasting method, etc., it cannot be said uniformly, but it is the largest in controlling the blunt state. The factor is the etching amount. Etching amount here is the thickness of the plating layer cut by etching. If the etching amount is small, the effect of blunting the surface shape of the unevenness obtained by a blast or the like is insufficient, and the optical properties of the antiglare film obtained by transferring the unevenness shape to the transparent film are not very good. On the other hand, if the etching amount is too large, the uneven shape is almost eliminated, and the mold becomes almost flat. Therefore, the anti-glare property is not exhibited. Therefore, it is preferable to make etching amount into 1 micrometer or more and 20 micrometers or less, and it is more preferable that they are 2 micrometers or more and 10 micrometers or less.

In the case of adopting copper plating as a dull process, the dull state of the unevenness varies according to the size and depth of the unevenness obtained by the method of the base metal, the blast, etc., and the type and thickness of the plating, and so on Needless to say, the biggest factor in controlling the dull state is the plating thickness. When the thickness of a copper plating layer is thin, the effect of blunting the surface shape of the uneven | corrugated obtained by methods, such as a blast, is inadequate, and the optical characteristic of the anti-glare film obtained by transferring the uneven | corrugated shape to a transparent film does not improve very much. On the other hand, if the plating thickness is too thick, the productivity will be deteriorated, and since the uneven shape will almost disappear, the anti-glare property will not be exhibited. Therefore, it is preferable to make thickness of copper plating into 1 micrometer or more and 20 micrometers or less, and it is more preferable that they are 4 micrometers or more and 10 micrometers or less.

Thus, after blunting the surface shape of the base material on which the unevenness is formed on the surface of copper plating or nickel plating, by further performing chromium plating, the surface of the unevenness can be further blunted and a metal plate having a high surface hardness is made. . The dull state of the unevenness at this time also varies depending on the size and depth of the unevenness obtained according to the type of the base metal, the blast, etc., and the type and thickness of the plating. The biggest factor is also the plating thickness. When the thickness of the chromium plating layer is thin, the effect of blunting the surface shape of the unevenness obtained before the chrome plating process is insufficient, and the optical properties of the antiglare film obtained by transferring the uneven shape to the transparent film are not very good. On the other hand, when plating thickness is too thick, productivity will worsen and a protrusion type plating defect called a nodule will generate | occur | produce. Therefore, the thickness of the chromium plating is preferably set to 1 µm or more and 10 µm or less, and more preferably 2 µm or more and 6 µm or less.

Chromium plating is one which gives gloss, high hardness, low coefficient of friction, and good release properties. Although the kind of chromium plating is not specifically limited, It is preferable to use the chromium plating which expresses favorable gloss called so-called gloss chrome plating, decorative chromium plating, etc. Chromium plating is usually performed by electrolysis, and an aqueous solution containing chromic anhydride (CrO ₃ ) and a small amount of sulfuric acid is used as the plating bath. By adjusting the current density and the electrolysis time, the thickness of the chromium plating can be controlled.

It is preferable that the Vickers hardness of the metal mold | die surface to which chrome plating was given is 800 or more, More preferably, it is 1,000 or more. When the Vickers hardness is low, the durability at the time of use of the mold decreases, and the decrease in hardness in chromium plating is likely to cause an abnormality in the plating bath composition, electrolytic conditions, etc. during the plating treatment, It is highly likely to have an undesirable effect.

As background art, Patent Document 1 (Japanese Laid-Open Patent Publication No. 2002-189106) and Patent Document 4 (Japanese Patent Laid-Open Publication No. 2004-90187) published above disclose chromium plating on the surface of a metal substrate to be a die. However, depending on the type of base and chromium plating before plating of the mold, the surface may be rough after plating or a large number of minute cracks due to chromium plating may occur. As a result, the antiglare film produced Optical properties proceed in undesirable directions. The thing whose plating surface was rough is not suitable for the metal mold | die for anti-glare film. This is because, in general, polishing of the plating surface after chrome plating is performed in order to eliminate roughness, but as described later, polishing of the surface after plating is not preferable in the present invention. In the present invention, copper plating or nickel plating is applied to the base metal to solve such a problem that is likely to occur in chromium plating.

If the process of blunting the uneven shape is not performed before the chromium plating, the chromium plating must be thickened to sufficiently blunt the sharp part of the uneven shape produced by bumping the fine particles. However, when the thickness of chromium plating is made too thick, nodule will become easy to generate | occur | produce, and it is unpreferable. In addition, when the thickness of the chromium plating is thinned, since the uneven shape produced by hitting the fine particles cannot be blunted sufficiently and a mold having a desired surface shape cannot be obtained, the anti-glare film produced by using the mold also has excellent anti-glare performance. Does not indicate.

In Patent Document 1 (Japanese Patent Laid-Open No. 2002-189106), it is described that chrome plating is performed after forming an uneven surface on a roller chromium plated by iron sandblasting method or bead short method. In addition, Patent Document 3 (Japanese Patent Laid-Open No. 2004-29240) and Patent Document 4 (Japanese Patent Laid-Open No. 2004-90187) disclose that the bead short method or the blast treatment is applied to the roll surface. It is. However, there is no mention of a method of blunting the surface irregularities by subjecting the fine particles to form an uneven shape and then performing a process of actively blunting the surface shape, followed by chrome plating. As described above, an antiglare film exhibiting excellent antiglare performance could not be produced unless a process of actively blunting the surface shape was performed.

Moreover, it is not preferable to apply plating other than chromium plating to the metal surface which made uneven | corrugated. Because in plating other than chromium, hardness and abrasion resistance are lowered, so that durability as a mold decreases, irregularities are worn out during use, and the mold is damaged. In the anti-glare film obtained from such a metal mold | die, the possibility of not being able to acquire sufficient anti-glare function is high, and also the possibility of a defect generate | occur | producing on a film becomes high.

After chrome plating, it is advantageous to use a chromium plating surface as an uneven surface of a metal mold as it is, without polishing the surface. Although it is described in the said patent document 4 (Unexamined-Japanese-Patent No. 2004-90187) to grind the surface after plating, it is unpreferable in this invention to grind the chromium plating surface. The reason for this is that, by polishing, flat portions are formed on the outermost surface, which may cause deterioration of the optical characteristics, and because the shape control factor increases, making shape control with good reproducibility difficult. FIG. 8 shows a process of blunting the concave-convex shape obtained by hitting the fine particles, in this case, after performing the etching treatment shown in FIG. 7 (C1), and then polishing the surface subjected to chromium plating shown in (D1) in the same manner. It is a cross-sectional schematic diagram of the metal plate with a flat surface. By polishing, some convexities of the surface unevenness 38 of the chromium plating layer 37 formed on the surface of the copper or nickel plating layer 32 are shaved, and a flat surface 39 is formed. 8 shows an example of the case where the chromium plated surface is polished after etching shown in FIG. 7 (D1). However, even when the chrome plated after copper plating shown in FIG. Similarly, a flat surface is created.

[Method for Producing Anti-glare Film]

Next, the process of manufacturing an anti-glare film is demonstrated using the metal mold | die obtained in this way. An anti-glare film can be obtained by transferring the shape of the metal mold | die obtained by the method similar to the above to a transparent resin film. It is preferable to perform transfer to the film of a mold shape by embossing. As embossing, the UV embossing method using a photocurable resin and the hot embossing method using a thermoplastic resin are illustrated.

In the UV embossing method, the photocurable resin layer is formed on the surface of the transparent support, and the photocurable resin layer is cured while pressing the concave and convex surface of the mold, thereby transferring the concave and convex surface to the photocurable resin layer. Specifically, the ultraviolet curable resin is coated on the transparent support, and the coated ultraviolet curable resin is brought into close contact with the uneven surface of the mold, and the ultraviolet curable resin is irradiated from the transparent support side to cure the ultraviolet curable resin. The shape of the mold is transferred to the ultraviolet curable resin by peeling the support from which the ultraviolet curable resin layer is formed from the mold. The kind of ultraviolet curable resin is not specifically limited. In addition, although expressed as an ultraviolet curable resin, by selecting a photoinitiator suitably, it can also be set as resin which can be hardened | cured by visible light which has a wavelength longer than an ultraviolet-ray. That is, the ultraviolet curable resin here is a general term which also included such visible-light curable resin. On the other hand, in the hot embossing method, the transparent thermoplastic resin film is pressed onto the mold in a heated state, and the surface shape of the mold is transferred to the thermoplastic resin film. Among these embossing methods, from the viewpoint of productivity, the UV embossing method is preferable.

The transparent support used for the production of the antiglare film may be a substantially optically transparent resin film, for example, an amorphous ring containing triacetyl cellulose, polyethylene terephthalate, polymethyl methacrylate, polycarbonate, and norbornene-based compound as a monomer. A solvent cast film, an extruded film, etc. which consist of thermoplastic resins, such as a polyolefin, can be used.

As ultraviolet curing resin, a commercially available thing can be used. For example, polyfunctional acrylates, such as trimethylolpropane triacrylate and pentaerythritol tetraacrylate, may be used alone or in combination of two or more thereof, and may be used as "Irgacure 907" and "Igacure". What mix | blended photoinitiators, such as 184 "(above, Chiba Specialty Chemical Co., Ltd. product) and" Lucirine TPO "(made by BASF Corporation), can be made into ultraviolet curable resin.

The thermoplastic transparent resin film used in the hot embossing method may be any transparent material, as long as it is substantially transparent. For example, an amorphous ring containing polymethyl methacrylate, polycarbonate, polyethylene terephthalate, triacetyl cellulose, and norbornene-based compound as a monomer. A solvent cast film, an extruded film, etc. of thermoplastic resins, such as a polyolefin, can be used. These transparent resin films can also be used as a transparent support body in the case of employing the UV embossing method described above.

The anti-glare film of this invention uses the metal mold | die with which the unevenness | corrugation was formed in the predetermined shape, transfers to the resin which apply | coated the uneven | corrugated surface of the metal mold | die on the transparent support body, and then peels off the resin from which the uneven | corrugated surface was transferred from the metal mold | die Therefore, it is preferable to form a surface fine uneven | corrugated shape, and in resin used for transcription | transfer, microparticles whose average particle diameters are 5 micrometers or more and 15 micrometers or less, and whose refractive index difference with a binder resin are 0.01 or more and 0.06 or less with respect to 100 weight part of binder resins, It is preferable to contain 10 weight part-100 weight part.

When the average particle diameter of the microparticles | fine-particles mix | blended with binder resin is less than 5 micrometers, since the value of the wide angle side of a transmission scattering profile rises and, as a result, reduces contrast when it applies to an image display apparatus, it is unpreferable. On the contrary, when the average particle diameter exceeds 15 micrometers, as mentioned later, it becomes a tendency for the film thickness to become thick in order to bury particle | grains from a viewpoint in which it is preferable to fully immerse particle | grains in binder resin. As a result, problems such as curling and agglomeration are likely to occur during resin coating.

In addition, when the difference in refractive index between the fine particles and the binder resin is less than 0.01, the internal scattering effect by the fine particles is reduced, so that a large amount of fine particles are added to the binder resin in order to give a predetermined scattering characteristic and haze to the antiglare layer and to eliminate glare. It is necessary to add to and not preferable from the viewpoint of completely embedding the fine particles in the binder resin. On the other hand, when this refractive index difference exceeds 0.06, since the refractive index difference is large, the reflectance in the interface of a binder resin and microparticles | fine-particles increases, as a result, backscatter rises and the total light transmittance falls, and it is unpreferable. Since the hardened | cured material shows many refractive indexes before and after 1.50, as for the ultraviolet curable resin as mentioned above, microparticles | fine-particles can be suitably selected from the thing whose refractive index is about 1.40-1.60 according to the design of an anti-glare film. As microparticles | fine-particles, a resin bead and also an almost spherical thing are used preferably. Examples of such suitable resin beads are listed below.

Melamine beads (refractive index 1.57),

Polymethyl methacrylate beads (refractive index 1.49),

Methyl methacrylate / styrene copolymer resin beads (refractive index 1.50-1.59),

Polycarbonate beads (refractive index 1.55),

Polyethylene beads (refractive index 1.53),

Polystyrene beads (refractive index 1.6),

Polyvinyl chloride beads (refractive index 1.46),

Silicone resin beads (refractive index 1.46) and the like.

In addition, these fine particles do not affect the uneven shape of the surface, that is, it is preferable to embed the particles completely in the binder resin. This is because, when the fine particles protrude from the surface, the surface irregularities are changed in accordance with the shape of the fine particles, which affects the reflection characteristics (antiglare performance, light fading, etc.) of the antiglare film. In this way, when the fine particles protrude to the surface, in addition to the surface shape of the mold described above, the shape, concentration, dispersibility, etc. of the particles must be taken into consideration, so that the surface shape must be designed, and the design and control of the surface shape is complicated. It becomes difficult and it becomes difficult to obtain the predicted characteristic. Therefore, it is preferable that the surface shape mainly affecting the reflection characteristics is controlled only by the mold, and the scattering characteristics are independently controlled by a combination of resin and particles.

[Antiglare Polarizer]

The anti-glare film of the present invention configured as described above has excellent anti-glare effect, effectively prevents fading of light, and can effectively suppress the occurrence of glare and lowering of contrast, and therefore has excellent visibility when mounted on an image display device. It becomes. When an image display apparatus is a liquid crystal display, this anti-glare film can be applied to a polarizing plate. That is, although the polarizing plate generally has the thing in which the protective film was bonded to at least one side of the polarizer which consists of a polyvinyl alcohol-type resin film in which the iodine or a dichroic dye was adsorption-oriented, the anti-glare film of this invention It can be set as the anti-glare polarizing plate by comprising this, and bonding a polarizer and the anti-glare film of this invention on the transparent support side of this anti-glare film. In this case, the other surface of a polarizer may be as it is, another protective film or an optical film may be laminated | stacked, and the adhesive layer for bonding to a liquid crystal cell may be formed. Moreover, the anti-glare film of this invention can be bonded by the transparent support body side to the polarizing plate which the protective film was bonded to at least one side of the polarizer, and can also be set as an anti-glare polarizing plate. Moreover, in the polarizing plate with which the protective film was bonded, it can also be set as an anti-glare polarizing plate by providing the above-mentioned anti-glare unevenness to the surface of this single-sided protective film.

[Image display device]

The image display apparatus of this invention combines the anti-glare film or anti-glare polarizing plate which has a specific surface shape as demonstrated above with an image display element. Here, the image display element includes a liquid crystal cell in which liquid crystal is enclosed between upper and lower substrates, and a liquid crystal panel which displays an image by changing the alignment state of the liquid crystal by applying a voltage is typical. In addition, other plasma display panels and CRT displays The anti-glare film of the present invention can also be applied to various known displays such as an organic EL display. And an image display apparatus is comprised by arrange | positioning said anti-glare film at the visual recognition side rather than an image display element. At this time, it is arrange | positioned so that the uneven surface of an anti-glare film, ie, an anti-glare layer side, may become an outer side (viewing side). The antiglare film may be directly bonded to the surface of the image display element, and when the liquid crystal panel is used as the image display means, for example, as described above, the antiglare film may be bonded to the surface of the liquid crystal panel. Thus, the image display apparatus provided with the anti-glare film of this invention can scatter an incident light by the unevenness | corrugation of the surface which an anti-glare film has, and can apply a projected image, and will provide the outstanding visibility.

In addition, even when the anti-glare film of the present invention is applied to a high-definition image display device, the glare seen in the conventional anti-glare film does not occur, and sufficient projection prevention, prevention of light fading, suppression of glare, and suppression of decrease in contrast It combines performance.

<Example>

Although an Example is shown to the following and this invention is demonstrated to it further more concretely, this invention is not limited by these examples. In the example,% and part which show content-usage-amount are a basis of weight unless it mentions specially. In addition, the evaluation method of the metal mold | die or anti-glare film in the following examples is as follows.

1.Measuring Vickers Hardness of Mold

Vickers hardness was measured by the method based on JISZ2244 using the ultrasonic hardness tester "MIC10" by the Krautkramer company. The measurement was performed on the surface of the mold itself.

2. Measurement of optical properties of antiglare film

(Scattering profile)

The antiglare film is bonded to the glass substrate so that the uneven surface becomes the surface, and the parallel light from the He-Ne laser is irradiated from the direction inclined at a predetermined angle with respect to the film normal from the glass surface side, and the antiglare film uneven surface side The transmitted scattered light intensity in the film normal direction was measured at. Both the "3292 03 optical power sensor" and the "3292 optical power meter" by Yokokawa Denki Co., Ltd. were used for the measurement of a reflectance.

(Reflection profile)

The uneven surface of the antiglare film is irradiated with parallel light from the He-Ne laser from a direction inclined at 30 ° to the film normal, and the angle change of reflectance in the plane including the film normal and the irradiation direction is measured. It was. Both the "3292 03 optical power sensor" and the "3292 optical power meter" by Yokokawa Denki Co., Ltd. were used for the measurement of a reflectance.

(Haze)

The haze of the anti-glare film was measured using the haze meter "HM-150" type made by Murakami Shikisaiki Jutsu Kenkyu Sho Co., Ltd. based on JIS K 7136. In order to prevent curvature of a sample, it bonded to the glass substrate so that the uneven surface might be surface using the optically transparent adhesive agent, and the whole haze was measured in that state. When the internal haze was measured, a triacetyl cellulose film having almost zero haze was adhered to the antiglare film uneven surface with glycerin.

(Reflection sharpness)

The reflection sharpness of the anti-glare film was measured using the fissure measuring instrument "ICM-1DP" manufactured by Sugashi Kenki Co., Ltd. in accordance with JIS K 7105. Also in this case, in order to prevent curvature of a sample, it bonded to the glass substrate so that an uneven surface might become a surface using the optically transparent adhesive, and used for the measurement. In addition, in order to prevent reflection from the back glass surface, a black acrylic resin plate having a thickness of 2 mm is adhered to water and adhered to the glass surface of the glass plate with the antiglare film, and light is incident from the sample (antiglare film) side in this state. The measurement was performed. As mentioned above, the measured value here is the sum total of the value measured using the three types of optical combs whose width | variety of a arm part and a wrist is 0.5 mm, 1.0 mm, and 2.0 mm, respectively.

3. Measurement of surface shape of antiglare film

The surface shape of the anti-glare film was measured using the confocal microscope "PLμ2300" manufactured by Sensofar. Also in this case, in order to prevent the bending of a sample, it bonded to the glass substrate so that the uneven surface might become the surface using the optically transparent adhesive, and used for the measurement. At the time of measurement, the magnification of the objective lens was 50 times, and the measurement was carried out by reducing the resolution. This is because when the measurement is performed at a high resolution, fine irregularities on the surface of the sample are measured to cause a disturbance in the count of the convex portion.

(Arithmetic mean height in section curve (Pa), maximum section height (Pt) and mean length (PSm))

Based on the measurement data obtained above, arithmetic mean height Pa, maximum cross-sectional height Pt, and average length PSm were calculated | required by calculation based on JISB0601.

(Number of convexities)

Based on the three-dimensional coordinate values of each surface of the antiglare film obtained in the above measurement, the number of the convex portions existing in the region of 200 μm × 200 μm was determined according to the algorithm described with reference to FIG. 5.

(Average Area of Voronoi Polygons when Voronoi Divided)

Based on the three-dimensional coordinate values of each surface of the antiglare film obtained in the above measurement, the calculation was first performed based on the algorithm described with reference to FIGS. 5 and 6 to obtain an average area of the Voronoi polygon.

4. Evaluation of antiglare performance of antiglare film

(Visual evaluation of projection, light fading and texture)

In order to prevent reflection from the back surface of the antiglare film, the antiglare film is bonded to the black acrylic resin plate so that the uneven surface becomes the surface, and visually observed from the uneven surface side in the bright room where the fluorescent lamp is turned on, and whether or not the projection of the fluorescent lamp is present, The degree and texture of the light fading were visually evaluated. Projection, light fading, and texture were evaluated according to the following criteria in three steps of 1 to 3, respectively.

Projection 1: No projection is observed.

     2: The projection is slightly observed.

     3: The projection is clearly observed.

Light fading 1: No light fading is observed.

        2: A little light fading is observed.

        3: The fading of light is clearly observed.

Texture 1: The texture is fine and the texture is good.

     2: The texture is slightly rough and the texture is slightly bad.

     3: The texture is obviously rough and the texture is bad.

(Evaluation of the glare)

Glare was evaluated by the following method. That is, first, the photomask which has the pattern of a unit cell as shown by the top view in FIG. 9 was prepared. In this figure, the unit cell 40 has a line width of 10 占 퐉 and a hook-shaped chromium light shielding pattern 41 formed on a transparent substrate, and a portion where the chromium light shielding pattern 41 is not formed is an opening 42. ) Here, a unit cell having a size of 254 μm × 84 μm (vertical × horizontal in the drawing), and thus an opening dimension of 244 μm × 74 μm (vertical × horizontal in the drawing) was used. The unit cells shown in figure are lined up in the vertical and horizontal direction, and form a photo mask.

And as shown in a typical cross section in FIG. 10, the chrome light shielding pattern 41 of the photomask 43 is put up in the light box 45, and the antiglare film 11 is attached to the glass plate 47 with an adhesive. The bonded sample is placed on the photo mask 43 so that the uneven surface becomes a surface. In the light box 45, the light source 46 is disposed. In this state, the degree of glare was sensory evaluated in seven steps by visual observation at a position 49 about 30 cm away from the sample. Level 1 is a state in which no glare is recognized at all, level 7 corresponds to a state in which severe glare is observed, and level 3 is a state in which very little glare is observed.

(Evaluation of contrast)

The polarizing plate of both front and back was peeled from the commercially available liquid crystal television ("LC-42GX1W" by Sharp Corporation). Instead of these original polarizing plates, the polarizing plate "Sumikaran SRDB831E" manufactured by Sumitomo Kagaku Co., Ltd. was bonded to each other through the pressure-sensitive adhesive so that each absorption axis coincides with the absorption axis of the original polarizing plate, and also the display was performed. On the surface side polarizing plate, the anti-glare film shown in each of the following examples was bonded through the adhesive so that the uneven surface may be a surface. The liquid crystal television obtained in this way was started in the dark room, the brightness | luminance in the black display state and the white display state was measured using the luminance meter "BM5A" type from Topcon Co., Ltd., and the contrast was computed. The contrast is expressed by the ratio of the luminance of the white display state to the luminance of the black display state.

Example 1

(A) Production of embossing mold

It was prepared that copper ballad plating was performed on the surface of an iron roll (STKM13A according to JIS) having a diameter of 200 mm. Copper ballad plating consists of a copper plating layer / thin silver plating layer / surface copper plating layer, and the thickness of the whole plating layer was about 200 micrometers. The copper-plated surface was mirror-polished, and the zirconia bead "TZ-B53" manufactured by Tosoh Corporation was used on the polished surface using a blast device (manufactured by Fuji Seisakusho Co., Ltd.) (brand name, average particle) 53 micrometers in diameter) is blasted on condition of bead consumption of 8 g / cm <2> (per surface area of a roll), blast pressure 0.15 Mpa (gauge pressure), and the distance of 450 mm from the nozzle which injects microparticles to a metal surface, Made irregularities in The obtained copper plating iron roll having the unevenness was etched with a cupric chloride aqueous solution. The etching amount at that time was set to be 8 micrometers. Then, the chrome plating process was performed and the metal mold for embossing was produced. At this time, the chromium plating thickness was set to 4 µm. The Vickers hardness of the obtained metal mold | die was 1,000.

(B) Production of antiglare film

Each of the following components was dissolved in ethyl acetate at a solid content concentration of 60%, and an ultraviolet curable resin composition having a refractive index of 1.53 was obtained after curing.

Pentaerythritol triacrylate 60 parts

40 parts of polyfunctional urethane acrylate

(Reaction product of hexamethylene diisocyanate and pentaerythritol triacrylate)

With leveling agent

Solid content (including resin beads) was added to this ultraviolet curable resin composition after 25 parts of methyl methacrylate / styrene copolymer resin beads having an average particle diameter of 8 µm and a refractive index of 1.565 were added per 100 parts of the ultraviolet curable resin. Ethyl acetate was added so that the density | concentration of might be 50%, and the coating liquid was prepared.

On the 80-micrometer-thick triacetyl cellulose (TAC) film, the said coating liquid was apply | coated so that the coating film thickness after drying might be set to 10 micrometers, and it dried for 3 minutes in the dryer set to 60 degreeC. The film after drying was pressed and adhered to the uneven surface of the metal mold | die produced by (A) with a rubber roll so that an ultraviolet curable resin composition layer might become a metal mold | die side. In this state, the light from the high-pressure mercury lamp of 20 MW / cm <2> of intensity | strength was irradiated so that it might become 200 mJ / cm <2> by h-ray-converted light quantity, and the ultraviolet curable resin composition layer was hardened. Thereafter, the TAC film was peeled from the mold for each cured resin to obtain a transparent antiglare film made of a laminate of a cured resin having a concave-convex surface and a TAC film.

(C) evaluation of antiglare film

About the obtained anti-glare film, optical characteristic, uneven surface shape, and anti-glare performance were evaluated in accordance with the above-mentioned method, and the result was shown in Table 1 with the manufacturing conditions of a metal mold | die, the kind and quantity of microparticles | fine-particles used for anti-glare layer preparation. In addition, the graph of the transmission scattering profile is shown in FIG. 11, and the graph of the reflection profile is shown in FIG. In addition, in Table 1, (A) summarizes the etching amount at the time of metal mold manufacture, the kind and quantity of microparticles | fine-particles used for anti-glare layer preparation, (B) summarizes the optical characteristics of an anti-glare film, and (C) Summarizes the surface shape and anti-glare performance of the anti-glare film. In addition, the detail of reflection sharpness in (B) of Table 1 is as follows.

Reflection sharpness

0.5 mm optical comb: 1.4%

1.0 mm optical comb: 5.4%

2.0 mm optical comb: 9.6%

16.4% in total

[Example 2]

The etching amount at the time of metal mold | die manufacture was changed like Table 1, except having carried out similarly to Example 1, the metal mold | die for embossing which has an unevenness | corrugation on the surface was produced. The Vickers hardness of the obtained metal mold | die was 1,000. Using this metal mold | die, it carried out similarly to Example 1, and produced the transparent anti-glare film which consists of a laminated body of cured resin which has unevenness | corrugation on the surface, and a TAC film.

EXAMPLES 3 AND 4

The same mold as in Example 1 was used, and the amount of the fine particles used for preparing the antiglare layer and / or the amount of addition to 100 parts by weight of the ultraviolet curable resin was changed as shown in Table 1, except that the same as in Example 1, The transparent anti-glare film which consists of a laminated body of cured resin and uneven | corrugated TAC film which has an unevenness | corrugation was produced. In addition, the microparticles | fine-particles used in Example 3 are the same methyl methacrylate / styrene copolymer resin beads as Example 1, The microparticles | fine-particles used in Example 4 are polymethacrylic acid whose average particle diameter is 8 micrometers, and refractive index is 1.490. Methyl beads.

All of the anti-glare films obtained in Examples 2 to 4 show the optical properties, the surface shape, and the anti-glare performance of these anti-glare films in Table 1 together with the data of Example 1. In addition, the graph of the transmission scattering profile and the reflection profile of these anti-glare films was shown to FIG. 11 and FIG. 12 with the data of Example 1, respectively.

[Comparative Examples 1 and 2]

In Comparative Example 1, the same mold as in Example 1 was used, and in Comparative Example 2, the same mold as in Example 2 was used, and all of the ultraviolet curable resin compositions containing no resin beads were used. The transparent anti-glare film which consists of a laminated body of cured resin and a TAC film which have an unevenness | corrugation on the surface was produced. The optical characteristic, surface shape, and anti-glare performance of the obtained anti-glare film were shown in Table 1 together with the data of Example 1. In addition, the graph of the transmission scattering profile of these anti-glare films was shown in FIG. 13, and the graph of the reflection profile was shown in FIG.

As shown in Table 1, Examples 1 and 2 satisfying the requirements of the present invention exhibit excellent anti-glare performance (low projection and good texture), and do not cause glare or light fading, and are high even when applied to an image display device. Contrast was shown. In addition, in Examples 3 and 4 in which the internal haze was increased, the contrast decreased slightly compared with Examples 1 and 2, but it was found that glare was more effectively suppressed.

On the other hand, in Comparative Examples 1 and 2, since the surface shape is almost the same as in Examples 1 and 2, respectively, while showing excellent anti-glare performance, no light fading occurred and a high contrast value was shown, but the relative scattered light intensity T Since at least one of (20) and T (30) is less than the provision of the present invention, the glare is strong, and when applied to an image display device, the visibility is significantly reduced.

Here, Example 1, 3, and 4 and Comparative Example 1 produced the anti-glare film using the same mold, and Example 2 and Comparative Example 2 also produced the anti-glare film using the same mold. And the reflection characteristic of the anti-glare film produced using these same metal molds is almost equivalent, and it turns out that the added microparticles | fine-particles do not affect the surface shape.

Comparative Examples 3 to 5

To the same ultraviolet curable resin composition (before the addition of the resin beads) as used in Example 1, 10 parts of porous silica fine particles having an average particle diameter of about 10 µm and a refractive index of 1.46 were added per 100 parts of the ultraviolet curable resin, and also in Comparative Example 4 and In 5, methyl methacrylate / styrene copolymer resin beads having an average particle diameter of 3 µm and a refractive index of 1.57 were added and dispersed in the amounts shown in Table 2 per 100 parts of the ultraviolet curable resin, and then the solid content (silica fine particles and resin beads Ethyl acetate was added so that the density | concentration of (included) may be 30%, and the coating liquid was prepared.

On the 80-micrometer-thick triacetyl cellulose (TAC) film, the said coating liquid was apply | coated so that the coating film thickness after drying might be 4 micrometers, and it dried for 3 minutes in the dryer set to 60 degreeC. From the photocurable resin composition layer side of the film after drying, the light from the high pressure mercury lamp of 20 kW / cm <2> intensity | strength is irradiated so that it may become 200 mJ / cm <2> by h-ray-converted light quantity, harden an ultraviolet curable resin composition layer, and the unevenness may be made to the surface The transparent anti-glare film which consists of a laminated body of cured resin which has and TAC film was obtained. In this anti-glare film, as can be seen from the relationship between the particle diameter (about 10 μm) of the silica fine particles and the coating film thickness (4 μm), the silica fine particles protrude on the surface of the anti-glare layer.

About the obtained anti-glare film, optical characteristic, uneven surface shape, and anti-glare performance were evaluated in accordance with the above-mentioned method, and the result was shown in Table 2 with the composition of resin. In Table 2, (A) summarizes the microparticles | fine-particles mix | blended with curable resin, (B) summarizes the optical characteristics of an anti-glare film, and (C) summarizes the surface shape and anti-glare performance of an anti-glare film. . In addition, the graph of the transmission scattering profile is shown in FIG. 15, and the graph of the reflection profile is shown in FIG.

As shown in Table 2, in Comparative Example 3, since the relative scattered light intensities T (20) and T (30) are less than the provisions of the present invention, the contrast did not decrease, but the glare was strong and applied to the image display device. At the time, the visibility was impaired. In Comparative Example 4, since the relative scattered light intensity T (20) of 20 ° incidence exceeded the definition of the present invention, the contrast was lowered to 1,800 or less, thereby impairing visibility. In addition, despite the fact that the average length PSm is large in the surface shape, the number of convex portions is small, the average area of the Voronoi polygon is large, and as a whole, the shape is larger than that specified in the present invention. Glare was not sufficiently suppressed. In Comparative Example 5, since the relative scattered light intensities T (20) and T (30) greatly exceeded the provisions of the present invention, glare did not occur, but contrast was greatly reduced. In Comparative Examples 3 to 5, the average length (PSm) was generally large, the average area of the Voronoi polygons exceeded the definition of the present invention, and the number of the convex portions was less than the provision of the present invention, resulting in a rough texture. It was a beautiful appearance.

[Comparative Examples 6-9]

Antiglare films "AG3", "AG5", "SL6", "CV2", which are used as antiglare layers in the polarizing plate "Sumikaran" sold by Sumitomo Chemical Co., Ltd. Examples 6-9), each optical characteristic, surface shape, and anti-glare performance were evaluated in accordance with the method mentioned above, and the result was shown in Table 3. In Table 3, (B) summarizes the optical characteristics of an anti-glare film, and (C) summarizes the surface shape and anti-glare performance of an anti-glare film. In addition, the graph of the transmission scattering profile is shown in FIG. 17, and the graph of the reflection profile is shown in FIG.

In Comparative Example 6, since the relative scattered light intensities T (20) and T (30) were less than those specified in the present invention, the contrast did not decrease, but the glare was strong and the visibility was remarkably decreased. In addition, since all the requirements of the surface shape deviate from the provisions of the present invention, the texture is poor and the appearance is tolerated. In the comparative example 7, since the relative scattered light intensity T 30 of 30 degrees incidence was less than the prescription | regulation of this invention, it became the result which a glare generate | occur | produced. In Comparative Examples 8 and 9, since the relative scattered light intensities T (20) and T (30) were large, glare did not occur, but the contrast was greatly reduced. In Comparative Example 8, since the values of the reflectances R (40) and R (50) also exceeded the provisions of the present invention, the screen faded to a white light as a whole.

From the above result, it turns out that it is important to equip well-balanced requirements prescribed | regulated by this invention in order to achieve the optical characteristic made into the objective of this invention.

When the anti-glare film of the present invention exhibits excellent anti-glare performance, deterioration of visibility due to light fading is prevented, and when disposed on the surface of a high-definition image display device, glare does not occur and high contrast is expressed. The anti-glare polarizing plate which combined this anti-glare film with a polarizer also expresses the same effect. And the image display apparatus which arrange | positioned the anti-glare film or anti-glare polarizing plate of this invention is high in anti-glare performance, and becomes excellent in visibility.

Arranging the antiglare film of the present invention with respect to various displays such as a liquid crystal panel, a plasma display panel, a CRT display, an organic EL display, and the like so that the antiglare film is more visible than an image display element, thereby generating light fading and glare. Without this, the projected image can be applied, thereby providing excellent visibility.

Claims (12)

As an antiglare film in which an antiglare layer having a fine uneven surface is formed on a transparent support, The relative scattered light intensity T (20) in the anti-glare layer side normal line direction when light is incident at an incident angle of 20 ° from the transparent support side is 0.0001% or more and 0.0005% or less, An anti-glare film having a relative scattered light intensity T (30) of 0.00004% or more and 0.00025% or less in the antiglare layer-side normal line direction when light is incident from the transparent support side at an incident angle of 30 °. The light incident on the incident angle of 30 ° according to claim 1, The reflectance R (30) of 30 degrees of reflection angles is 0.05% or more and 2% or less, The reflectance R (40) of 40 degrees of reflection angles is 0.0001% or more and 0.005% or less, Anti-glare film whose reflectance R (50) of reflectance angle 50 degrees is 0.00001% or more and 0.0005% or less. The surface haze of the vertical incident light is 0.1% or more and 5% or less, Anti-glare film whose total haze is 5% or more and 25% or less. The antiglare according to claim 1, wherein a sum of reflection sharpness measured at an angle of incidence of 45 ° of light using three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm of a dark portion and a ridge is 40% or less. film. The cross-sectional curve of the uneven surface constituting the antiglare layer according to claim 1, Arithmetic mean height Pa is 0.05 micrometer or more and 0.2 micrometer or less, Maximum cross-sectional height Pt is 0.2 micrometer or more and 1 micrometer or less, Anti-glare film whose average length (PSm) is 15 micrometers or more and 30 micrometers or less. The anti-glare film of Claim 1 which has 50 or more 100 convex parts in the area | region of 200 micrometers x 200 micrometers in the uneven surface which comprises an anti-glare layer. The antiglare film according to claim 1, wherein the average area of the polygons formed when the surface is voronoi divided with the convex apexes of the uneven surface constituting the antiglare layer as a parent point is 100 µm ² or more and 1,000 µm ² or less. . The surface irregularities of the antiglare layer are formed by transfer from a mold having an uneven surface, and the antiglare layer has an average particle diameter of 5 µm or more and 15 µm or less with respect to 100 parts by weight of the binder resin. The anti-glare film which contains 10 weight part-100 weight part of fine particles whose refractive index difference with binder resin is 0.01 or more and 0.06 or less. The anti-glare film according to claim 8, wherein the fine particles are completely embedded in the anti-glare layer and do not affect the surface shape. The antiglare film according to claim 1, wherein a low reflection film is formed on the uneven surface of the antiglare layer. A polarizer and the antiglare film as described in any one of Claims 1-10 are bonded by the transparent support body side of the said antiglare film, The anti-glare polarizing plate characterized by the above-mentioned. The anti-glare film of any one of Claims 1-10 or the anti-glare polarizing plate of Claim 11, and an image display element are provided, The said anti-glare film or anti-glare polarizing plate is an image with the anti-glare layer side outside. It is arrange | positioned at the visual recognition side of a display element, The image display apparatus characterized by the above-mentioned.

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