KR20130133222A - Optical film manufacturing method, polarizing plate, and image display device - Google Patents

Optical film manufacturing method, polarizing plate, and image display device Download PDF

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KR20130133222A
KR20130133222A KR1020137016778A KR20137016778A KR20130133222A KR 20130133222 A KR20130133222 A KR 20130133222A KR 1020137016778 A KR1020137016778 A KR 1020137016778A KR 20137016778 A KR20137016778 A KR 20137016778A KR 20130133222 A KR20130133222 A KR 20130133222A
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South Korea
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active energy
energy ray
coating layer
film
region
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KR1020137016778A
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Korean (ko)
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KR101875244B1 (en
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쇼 간자키
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스미또모 가가꾸 가부시키가이샤
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0266—Local curing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/10—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation for articles of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/14—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length
    • B29C39/18—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11—Anti-reflection coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0034—Polarising

Abstract

Coating process which coats the coating liquid containing active energy ray curable resin on the base film 11 conveyed continuously, and forms the coating layer 12; 1st hardening process which irradiates an active energy ray to the head area | region A of the coating layer 12 from the coating layer 12 side; And the manufacturing method of the optical film containing the 2nd hardening process which irradiates an active energy ray from the base film 11 side in the state which pressed the surface of the mold to the surface of the coating layer 12 is provided. In a 1st hardening process, it is preferable to irradiate an active energy ray also to the rear region B of the coating layer 12 further. According to the present invention, it is possible to prevent the resin residue from being generated in the mold, thereby providing a method capable of continuously and efficiently producing the optical film without causing a problem such as a defect.

Description

Manufacturing method of optical film, polarizing plate, and image display apparatus {OPTICAL FILM MANUFACTURING METHOD, POLARIZING PLATE, AND IMAGE DISPLAY DEVICE}

This invention relates to the manufacturing method of the optical film which coats the coating liquid containing active energy ray curable resin on a base film, and hardens this. Moreover, this invention relates to the polarizing plate and the image display apparatus which used the said optical film.

The optical film which formed the resin layer which has a predetermined optical function by coating on a base film is used for various image display apparatuses, such as a liquid crystal display device, as an anti-glare film, a light-diffusion film, a hard-coat film, etc., for example. It is becoming.

Generally, the said resin layer with which an optical film is equipped is formed by coating the coating liquid containing active energy ray curable resin on a base film, and irradiating and hardening an active energy ray to the obtained coating layer. Depending on the optical properties required for the optical film, in order to give a desired shape to the surface of the resin layer, a mold having a predetermined surface shape may be pressed against the surface of the coating layer and cured in this state.

For example, in JP2007-76089-A, an ultraviolet curable resin is coated on a base film, and an ultraviolet-ray is irradiated in the state which contact | adhered the resin coating surface to the uneven roller (emboss roll) which rotates in synchronization with a base film, The method of hardening | curing and then peeling the laminated body of cured resin and a base film from an uneven roller is disclosed.

As in the method described in JP2007-76089-A, when an optical film is produced by curing a coating layer while pressing a mold such as an embossing roll on the surface of the coating layer, when the obtained optical film is peeled from the mold, the cured resin The "resin residue" which remained on the mold surface may generate | occur | produce. Resin residue is a continuous defect in the optical film obtained in continuous production of the optical film which forms a resin layer continuously on a long base film (resin adhesion to the optical film surface, the surface shape of an optical film, or Defects in optical characteristics). Moreover, removing and cleaning this whenever a resin residue arises greatly reduces manufacturing efficiency.

On the other hand, as a method of preventing the resin residue, it is considered to add a release agent to the coating liquid for forming the coating layer, or to apply the release agent to the mold surface in advance, but the mechanical strength and optical properties of the optical film by the addition of the release agent This may be damaged.

This invention is made | formed in view of the above, Comprising: It is providing the method which can prevent generation | occurrence | production of a resin residue, and can produce an optical film continuously and efficiently without a problem, such as a defect, by this.

MEANS TO SOLVE THE PROBLEM As a result of earnestly examining, peeling of the resin layer which produces a resin residue when peeling an optical film from a mold is a region where the film thickness of a coating layer becomes large rapidly, ie, the head of the film conveyance direction in a coating layer. It was found to be concentrated in the region (front end region of the coating layer) and the trailing region (back end region of the coating layer). Moreover, it was found that it is very effective to harden the area | region which peels easily of the said resin layer beforehand before the process of hardening a coating layer, pressing a mold as a means for preventing resin residue. In particular, curing the leading region of the coating layer in advance is very advantageous in preventing continuous defects when forming an optical film by continuously forming a resin layer on a long base film. On the other hand, hardening the tail region of a coating layer beforehand is very advantageous in preventing continuous defects when manufacturing the optical film of the next lot (using the next base film).

That is, the present invention includes the following.

[1] A coating process containing an active energy ray-curable resin on a substrate film continuously conveyed to form a coating layer, and irradiating active energy rays from the coating layer side to a leading region of the coating layer The manufacturing method of the optical film containing the 1st hardening process and the 2nd hardening process which irradiates an active energy ray from a base film side to a coating layer in the state which pressed the surface of a mold to the surface of a coating layer.

[2] In the area adjacent to the head region in contact with the head region irradiated with the active energy ray, the amount of accumulated light is gradually reduced from the irradiation amount to the head region in the head region adjacent to the head of the head region. The method as described in [1] which irradiates so that it may become.

[3] The active energy ray is an ultraviolet ray, and the irradiation amount of the active energy ray to the head region in the first curing step is 70 mJ / cm 2 or more and 400 mJ / cm 2 or less in the accumulated amount of ultraviolet rays in the UVA [1] or [ 2].

[4] The method according to [2] or [3], wherein the active energy ray is ultraviolet light and the rate of decrease of accumulated light amount in the UVA of the ultraviolet light is 1500 mJ / cm 2 · sec or less.

[5] The method according to any one of [1] to [4], wherein in the trailing region, active energy rays are irradiated to the trailing region from the coating layer side prior to the second curing step.

[6] In the trailing-adjacent region in contact with the trailing-edge region, prior to irradiation of the active energy ray into the trailing-edge region, the active energy ray is gradually increased from zero at the starting point of the trailing-edge region to the trailing edge. The method according to [5], wherein the irradiation is performed so that the amount of irradiation to the region is reached.

[7] The method according to [5] or [6], wherein the active energy ray is an ultraviolet ray and the dose of the active energy ray to the trailing region is 70 mJ / cm 2 or more and 400 mJ / cm 2 or less by the accumulated amount of ultraviolet rays in the UVA.

[8] The method according to [6] or [7], wherein the active energy ray is ultraviolet light and the increase rate of the accumulated light amount in the UVA of the ultraviolet light is 1500 mJ / cm 2 · sec or less.

[9] A polarizing plate comprising a polarizing film and an optical film produced by the method according to any one of [1] to [6], which is laminated on the polarizing film so that the base film side faces the polarizing film.

[10] An image display device comprising the polarizing plate according to [9] and an image display element, wherein the polarizing plate is disposed on the image display element such that the polarizing film is on the image display element side.

According to the method of the present invention, it is possible to effectively prevent the occurrence of resin residues when peeling the optical film from the mold. Thereby, in the continuous production of the optical film which continuously forms a resin layer on a long base film, it does not produce continuous defects (adherence of resin to a surface, defect of surface shape, optical characteristics, etc.), An optical film can be manufactured continuously and efficiently. In addition, since no removal and cleaning of the resin residues is required, manufacturing efficiency can be greatly improved. The optical film obtained by this invention can be preferably applied to image display apparatuses, such as a polarizing plate and a liquid crystal display device.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows typically a preferable example of the manufacturing method of the optical film of this invention, and the manufacturing apparatus used for this.
It is sectional drawing which shows a 1st hardening process typically.

<Production method of optical film>

The manufacturing method of the optical film of this invention has the following process:

[1] a coating step of coating a coating liquid containing an active energy ray-curable resin on a substrate film that is continuously conveyed to form a coating layer;

[2] a first curing step of irradiating an active energy ray to the head region of the coating layer from the coating layer side;

[3] a second curing step of curing the coating layer by irradiating an active energy ray from the base film side to the coating layer in a state where the surface of the mold is pressed against the surface of the coating layer

.

Hereinafter, each process is explained in full detail, referring drawings. FIG. 1: is a figure which shows typically a preferable example of the manufacturing method of the optical film of this invention, and the manufacturing apparatus used for this. 2 is sectional drawing which shows a 1st hardening process typically. The arrow in a figure shows the conveyance direction of a film, or the rotation direction of a roll.

[1] coating processes

In this process, the coating liquid containing active energy ray curable resin is coated on the base film conveyed continuously, and a coating layer is formed. In the coating step, for example, as shown in FIG. 1, the substrate film 11 is unwound continuously from a disk (a wound product of a long base film) attached to the film unwinding apparatus 31, and the coating apparatus 32 is used. It is possible to carry out by coating the coating liquid on the base film 11 using the ().

Coating of the coating liquid onto the base film 11 is performed by, for example, the gravure coating method, the microgravure coating method, the rod coating method, the knife coating method, the air knife coating method, the kiss coating method, the die coating method, or the like. Can be.

(Substrate film)

The base film 11 should just be translucent, for example, glass, a plastic film, etc. can be used. What is necessary is just to have moderate transparency and mechanical strength as a plastic film. Specifically, for example, cellulose acetate-based resins such as TAC (triacetylcellulose), acrylic resins, polycarbonate-based resins, polyester-based resins such as polyethylene terephthalate, polyolefin-based resins such as polyethylene and polypropylene, etc. Can be mentioned. The thickness of the base film 11 is 10-500 micrometers, for example, Preferably it is 10-300 micrometers from a viewpoint of thinning of an optical film, etc., More preferably, it is 20-300 micrometers.

For the purpose of improving the coating property of the coating liquid or the adhesiveness with the coating layer, various surface treatments may be performed on the surface (coating layer side surface) of the base film 11. Examples of the surface treatment include corona discharge treatment, glow discharge treatment, acid surface treatment, alkali surface treatment, ultraviolet irradiation treatment, and the like. Moreover, you may form another layer, such as a primer layer, on the base film 11, and to coat a coating liquid on this other layer.

In addition, when using the optical film by adhering to the polarizing film mentioned later, in order to improve the adhesiveness of a base film and a polarizing film, the surface (surface on the opposite side to a coating layer) of a base film is changed by various surface treatments. It is preferable to make it hydrophilic. You may perform this surface treatment after manufacture of an optical film.

(Coating amount)

The coating solution contains an active energy ray curable resin, and usually further contains a photopolymerization initiator (radical polymerization initiator). As needed, you may contain other components, such as light-transmitting microparticles | fine-particles and solvents, such as an organic solvent, a leveling agent, a dispersing agent, an antistatic agent, an antifouling agent, and surfactant.

(1) active energy ray curable resin

Active-energy-ray-curable resin can be ultraviolet curable resin, electron beam curable resin, etc., For example, what contains a polyfunctional (meth) acrylate compound can be used preferably. A polyfunctional (meth) acrylate compound is a compound which has at least 2 (meth) acryloyloxy group in a molecule | numerator. As a specific example of a polyfunctional (meth) acrylate compound, For example, ester compound of a polyhydric alcohol and (meth) acrylic acid, a urethane (meth) acrylate compound, a polyester (meth) acrylate compound, an epoxy (meth) The polyfunctional polymeric compound containing two or more (meth) acryloyl groups, such as an acrylate compound, etc. are mentioned.

As a polyhydric alcohol, for example, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, tetrapropylene glycol, polypropylene glycol, propanediol, butanediol Dihydric alcohols such as pentanediol, hexanediol, neopentylglycol, 2-ethyl-1,3-hexanediol, 2,2'-thiodieethanol and 1,4-cyclohexanedimethanol; And trihydric or higher alcohols such as trimethylolpropane, glycerol, pentaerythritol, diglycerol, dipentaerythritol, and ditrimethylolpropane.

As esterified product of polyhydric alcohol and (meth) acrylic acid, Specifically, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl Glycoldi (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolethane tri (meth) acrylate, tetramethylolmethane tri (meth) acrylate, 1,6-hexanedioldi (meth) acrylic Rate, tetramethylol methane tetra (meth) acrylate, pentaglycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, glycerin tri (meth) acrylate, dipenta Erythritol tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) arc There may be mentioned acrylate and the like.

As a urethane (meth) acrylate compound, the urethane-ized reaction material of the isocyanate which has several isocyanate groups in one molecule, and the (meth) acrylic acid derivative which has a hydroxyl group is mentioned. As an organic isocyanate which has several isocyanate groups in 1 molecule, such as hexamethylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, naphthalene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, dicyclohexyl methane diisocyanate, etc. The organic isocyanate which has two isocyanate groups in 1 molecule, the organic isocyanate which has three isocyanate groups in 1 molecule in which these organic isocyanate modified isocyanurate, adduct, and biuret is mentioned. As a (meth) acrylic acid derivative which has a hydroxyl group, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, 2-hydroxybutyl ( Meth) acrylate, 2-hydroxy-3-phenoxypropyl (meth) acrylate, pentaerythritol triacrylate, and the like.

As a polyester (meth) acrylate compound, polyester (meth) acrylate obtained by making a hydroxyl-containing polyester and (meth) acrylic acid react is preferable. The hydroxyl group containing polyester used preferably is a hydroxyl group containing polyester obtained by esterification reaction of the polyhydric alcohol, the compound which has a carboxylic acid and a some carboxyl group, and / or its anhydride. As a polyhydric alcohol, the thing similar to the compound mentioned above can be illustrated. Moreover, bisphenol A etc. are mentioned as phenols other than polyhydric alcohol. Formic acid, acetic acid, butyl carboxylic acid, benzoic acid etc. are mentioned as carboxylic acid. Examples of the compound having a plurality of carboxyl groups and / or anhydrides thereof include maleic acid, phthalic acid, fumaric acid, itaconic acid, adipic acid, terephthalic acid, maleic anhydride, phthalic anhydride, trimellitic acid and cyclohexanedicarboxylic anhydride. Can be mentioned.

Among the above-mentioned multifunctional (meth) acrylate compounds, hexanediol di (meth) acrylate, neopentylglycol di (meth) acrylate, diethylene glycol di (meth) from the point of the strength improvement and the availability of hardened | cured material. ) Ester compounds, such as an acrylate, a tripropylene glycol di (meth) acrylate, a trimethylol propane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, and dipentaerythritol hexa (meth) acrylate; Adducts of hexamethylene diisocyanate and 2-hydroxyethyl (meth) acrylate; Adducts of isophorone diisocyanate and 2-hydroxyethyl (meth) acrylate; Adducts of tolylene diisocyanate and 2-hydroxyethyl (meth) acrylate; Adduct of adduct modified isophorone diisocyanate and 2-hydroxyethyl (meth) acrylate; And an adduct of biuret-modified isophorone diisocyanate and 2-hydroxyethyl (meth) acrylate. In addition, these polyfunctional (meth) acrylate compounds can be used individually or in combination with 1 or more types, respectively.

Active energy ray curable resin may contain the monofunctional (meth) acrylate compound other than the said polyfunctional (meth) acrylate compound. As a monofunctional (meth) acrylate compound, for example, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, isobutyl (meth) acrylate, t-butyl (meth) Acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, hydroxybutyl (meth) acrylate, 2-hydroxybutyl (meth) acrylate, 2-hydroxy- 3-phenoxypropyl (meth) acrylate, glycidyl (meth) acrylate, acryloyl morpholine, N-vinylpyrrolidone, tetrahydrofurfuryl (meth) acrylate, cyclohexyl (meth) acrylate , 2-ethylhexyl (meth) acrylate, isobornyl (meth) acrylate, acetyl (meth) acrylate, benzyl (meth) acrylate, 2-ethoxyethyl (meth) acrylate, 3-methoxybutyl (Meth) acrylate, ethylcarbitol (meth) acrylate, phenoxy (meth) (Meth) acrylate, ethylene oxide modified phenoxy (meth) acrylate, propylene oxide (meth) acrylate, nonylphenol (meth) acrylate, ethylene oxide modified (meth) acrylate, propylene oxide modified nonylphenol (meth) acryl Latex, methoxydiethylene glycol (meth) acrylate, 2- (meth) acryloyloxyethyl-2-hydroxypropyl phthalate, dimethylaminoethyl (meth) acrylate, methoxytriethylene glycol (meth) acrylate, etc. (Meth) acrylates are mentioned. Each of these compounds may be used alone or in combination with one or more of them.

Moreover, active energy ray curable resin may contain the polymeric oligomer. By containing a polymerizable oligomer, the hardness of hardened | cured material can be adjusted. The polymerizable oligomer is, for example, the polyfunctional (meth) acrylate compound, that is, an ester compound of a polyhydric alcohol and (meth) acrylic acid, a urethane (meth) acrylate compound, a polyester (meth) acrylate compound or an epoxy. Oligomers such as dimers, trimers and the like such as (meth) acrylates.

As another polymerizable oligomer, the urethane (meth) acrylate oligomer obtained by reaction of the polyisocyanate which has at least 2 isocyanate group in a molecule | numerator, and the polyhydric alcohol which has at least 1 (meth) acryloyloxy group is mentioned. . As polyisocyanate, the polymer of hexamethylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, etc. are mentioned, The polyvalent which has at least 1 (meth) acryloyloxy group is mentioned. The alcohol is a hydroxyl group-containing (meth) acrylic acid ester obtained by an esterification reaction of a polyhydric alcohol with (meth) acrylic acid, and as a polyhydric alcohol, for example, 1,3-butanediol, 1,4-butanediol, 1,6 Hexanediol, diethylene glycol, triethylene glycol, neopentyl glycol, polyethylene glycol, polypropylene glycol, trimethylolpropane, glycerin, pentaerythritol, dipentaerythritol and the like. In this polyhydric alcohol having at least one (meth) acryloyloxy group, part of the alcoholic hydroxyl group of the polyhydric alcohol is esterified with (meth) acrylic acid, and the alcoholic hydroxyl group remains in the molecule.

Moreover, as an example of another polymerizable oligomer, polyester (meth) acrylate obtained by reaction of the compound which has a some carboxyl group, and / or its anhydride, and the polyhydric alcohol which has at least 1 (meth) acryloyloxy group Oligomers. As a compound which has a some carboxyl group, and / or its anhydride, the thing similar to what was described by the polyester (meth) acrylate of the said polyfunctional (meth) acrylate compound can be illustrated. Moreover, as a polyhydric alcohol which has at least 1 (meth) acryloyloxy group, the thing similar to what was described by the said urethane (meth) acrylate oligomer can be illustrated.

In addition to the polymerizable oligomers described above, examples of the urethane (meth) acrylate oligomers include compounds obtained by reacting isocyanates with hydroxyl groups of hydroxyl group-containing polyesters, hydroxyl group-containing polyethers or hydroxyl group-containing (meth) acrylic acid esters. Can be. The hydroxyl group containing polyester used preferably is a hydroxyl group containing polyester obtained by esterification reaction of the polyhydric alcohol, the compound which has a carboxylic acid and a some carboxyl group, and / or its anhydride. As a polyhydric alcohol, the compound which has a some carboxyl group, and / or its anhydride, the thing similar to what was described by the polyester (meth) acrylate compound of a polyfunctional (meth) acrylate compound can be illustrated, respectively. The hydroxyl group containing polyether used preferably is a hydroxyl group containing polyether obtained by adding 1 type, or 2 or more types of alkylene oxide and / or (epsilon) -caprolactone to a polyhydric alcohol. The polyhydric alcohol may be the same as that which can be used for the hydroxyl group-containing polyester. As hydroxyl-containing (meth) acrylic acid ester used preferably, the thing similar to what was described by the urethane (meth) acrylate oligomer of a polymeric oligomer can be illustrated. As isocyanate, the compound which has one or more isocyanate groups in a molecule | numerator is preferable, and divalent isocyanate compounds, such as tolylene diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate, are especially preferable.

These polymerizable oligomer compounds may be used alone or in combination with one or more of them.

(2) photopolymerization initiator

As a photoinitiator, an acetophenone type photoinitiator, a benzoin type photoinitiator, a benzophenone type photoinitiator, a thioxanthone type photoinitiator, a triazine type photoinitiator, an oxadiazole type photoinitiator, etc. are used, for example. Moreover, as a photoinitiator, 2,4,6- trimethylbenzoyl diphenyl phosphine oxide, 2,2'-bis (o-chlorophenyl) -4,4 ', 5,5'- tetraphenyl-, 1,2'-biimidazole, 10-butyl-2-chloroacridone, 2-ethylanthraquinone, benzyl, 9,10-phenanthrenequinone, camphorquinone, methyl phenylglyoxylate, titanocene compound and the like can also be used. Can be. The usage-amount of a photoinitiator is 0.5-20 weight part normally with respect to 100 weight part of active energy ray curable resins, Preferably it is 1-5 weight part.

(3) translucent fine particles

The light-transmitting fine particles are not particularly limited, and for example, organic fine particles made of acrylic resin, melamine resin, polyethylene, polystyrene, organic silicone resin, acryl-styrene copolymer, calcium carbonate, silica, aluminum oxide, carbonate Inorganic fine particles made of barium, barium sulfate, titanium oxide, glass, or the like can be used. Moreover, the balloon and hollow bead of an organic polymer can also be used. These light-transmitting fine particles may be used individually by 1 type, and may mix and use two or more types. The shape of the light-transmitting fine particles may be any of spherical, flat, plate, needle and irregular shapes.

The particle diameter and refractive index of the light-transmitting fine particles are not particularly limited. However, when the optical film is a light-diffusion film or an anti-glare film, the particle size is preferably in the range of 0.5 µm to 20 µm in terms of effectively expressing internal haze. Moreover, for the same reason, it is preferable that the difference between the refractive index of active energy ray curable resin after hardening, and the refractive index of translucent microparticles | fine-particles is the range of 0.04-0.15. The content of the light-transmitting fine particles is usually 3 to 60 parts by weight, preferably 5 to 50 parts by weight with respect to 100 parts by weight of the active energy ray curable resin. When content of translucent microparticles | fine-particles is less than 3 weight part with respect to 100 weight part of active energy ray curable resins, light diffusibility or anti-glare property may not be fully provided. On the other hand, when it exceeds 60 weight part, transparency of an optical film may be impaired, and also anti-glare property and light-diffusion property become high too much, and there exists a tendency for contrast to fall.

In addition, when using light-transmitting microparticles | fine-particles, in order to make the optical characteristic and surface shape of an optical film homogeneous, it is preferable that dispersion of light-transmitting microparticles | fine-particles in a coating liquid is isotropic dispersion.

The coating liquid may contain a solvent such as an organic solvent. As an organic solvent, Aliphatic hydrocarbons, such as hexane, cyclohexane, an octane; Aromatic hydrocarbons such as toluene and xylene; Alcohols such as ethanol, 1-propanol, isopropanol, 1-butanol and cyclohexanol; Ketones such as methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; Esters such as ethyl acetate, butyl acetate and isobutyl acetate; Glycol ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monoethyl ether, propylene glycol monomethyl ether and propylene glycol monoethyl ether; Esterified glycol ethers such as ethylene glycol monomethyl ether acetate and propylene glycol monomethyl ether acetate; Cellosolves such as 2-methoxyethanol, 2-ethoxyethanol and 2-butoxyethanol; Carbitols such as 2- (2-methoxyethoxy) ethanol, 2- (2-ethoxyethoxy) ethanol, 2- (2-butoxyethoxy) ethanol, etc. may be selected and used in consideration of viscosity and the like. Can be. These solvents may be used independently, and may mix and use several types as needed. After coating, it is necessary to evaporate the organic solvent. Therefore, it is preferable that boiling point is the range of 60 degreeC-160 degreeC. Moreover, it is preferable that the saturated vapor pressure in 20 degreeC is the range of 0.1 kPa-20 kPa.

When a coating liquid contains a solvent, it is preferable to set the drying process which evaporates a solvent and performs drying after the said coating process and before a 1st hardening process. Drying can be performed by letting the base film 11 provided with a coating layer pass the inside of the drying furnace 33, for example like the example shown in FIG. Drying temperature is suitably selected according to the kind of solvent to be used and a base film. Although it is the range of 20 degreeC-120 degreeC generally, it is not limited to this. Moreover, when there are two or more drying furnaces, you may change temperature for every drying furnace.

[2] first curing processes

This process irradiates an active energy ray from the coating layer side to the head region (front end region) of a coating layer, and advances this head region before the 2nd hardening process which hardens a coating layer in the state which pressed the mold surface. It is the process of hardening. The head region of the coating layer is a portion where the film thickness of the coating layer is remarkably thick, and is a portion where resin peeling is concentrated. By hardening this part before pressurizing the mold, it is possible to effectively prevent the resin residue from remaining in the mold. In particular, preventing the resin residue resulting from a coating layer head region is very advantageous in preventing the continuous defect which arises in the optical film obtained. That is, when a resin layer is continuously formed on a long base film and an optical film is produced, when a resin residue arises from a manufacturing start stage, this resin residue is manufactured using this long base film. It adversely affects the whole optical film.

The head region and the tail region described later can be specified by continuously measuring the film thickness. In the case of a coating layer obtained by a general coating method, almost all of the areas where the film thickness increases sharply are considerably smaller than 1 cm from the tip portion, or more than 1 cm from the rear end portion, unless the film thickness is intentionally changed. Since it is formed only in a small part, the said film thickness measurement etc. are not carried out practically, For example, 1 cm can be regarded as a front region and 1 cm from a rear end from the front end portion.

Irradiation of the active energy ray to the coating layer head region is described with reference to FIGS. 1 and 2, for example, the coating layer 12 that has passed through the coating apparatus 32 (the drying furnace 33 when drying). It can carry out by irradiating an active energy ray with respect to the base film 11 which has an active energy ray irradiation apparatus 10, such as an ultraviolet irradiation apparatus provided in the coating layer 12 side.

Specifically, the state where the active energy ray irradiation device 10 is turned on (the active energy ray is irradiated) before the leading region A of the coating layer 12 passes immediately below the active energy ray irradiation device 10. State), and after passing through the head region A, the active energy ray irradiation device 10 is set to the OFF state (the state where the irradiation of the active energy ray is stopped).

As an active energy ray, although it can select suitably from ultraviolet-ray, an electron beam, near-ultraviolet, visible light, near-infrared, infrared rays, X-rays, etc. according to the kind of active energy ray curable resin contained in a coating liquid, among these, an ultraviolet-ray and an electron beam are preferable, In particular, ultraviolet rays are particularly preferable in terms of easy handling and high energy.

As the ultraviolet light source, for example, a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, an ultra high pressure mercury lamp, a carbon arc lamp, a metal halide lamp, a xenon lamp, or the like can be used. Moreover, ArF excimer laser, KrF excimer laser, an excimer lamp, a synchrotron radiation, etc. can also be used. Among these, an ultra high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a xenon arc, and a metal halide lamp are used preferably.

Moreover, as an electron beam, 50-1000 keV emitted from various electron beam accelerators, such as a cocroft Walton type | mold, a half-degraph type | mold, a resonance transformation type | mold, an insulation core transformer type | mold, a linear type | mold dynamtron type | mold, and a high frequency type | mold, Preferably it is 100 Electron beams having an energy of ˜300 keV.

The irradiation amount to the head region in the first curing step is the accumulated light amount in the UVA of the ultraviolet ray when the active energy ray is the ultraviolet ray, preferably 70 mJ / cm 2 or more and 400 mJ / cm 2 or less, and more preferably It is 100 mJ / cm <2> or more and 250 mJ / cm <2> or less. If the amount of accumulated light is less than 70 mJ / cm 2, the degree of curing of the leading region A may be too low, resulting in resin peeling (and thus resin residue). Moreover, when it exceeds 400 mJ / cm <2>, as a result of an excessive hardening reaction, resin peeling is caused by film thickness difference and internal stress distortion at the boundary of a hardened part (front area | region A) and an unhardened part. It may occur.

After the irradiation of the active energy ray to the head region A in the first curing step, in the head adjoining region which is in contact with the head region, the active energy line is subsequently adjoined to the head adjoining region and the accumulated light quantity is adjoining the head from the irradiation amount to the head region. It is preferable to irradiate so that it may gradually decrease along the conveyance direction of a film to 0 at the end of an area | region. Thereby, since the grade of hardening in the head area | region A falls gradually to an unhardened state along the conveyance direction of a film, it is in the boundary of the hardened part (head region A) and the unhardened part of a coating layer. It is possible to prevent the resin peeling which may be caused by the film thickness difference or the distortion of the internal stress. Here, the head-adjacent region means an area adjacent to the head region and irradiated with an active energy ray while gradually decreasing from the dose to the head region until the irradiation amount becomes zero. The dose may start to decrease immediately from the start point of the head adjacent area that is in contact with the head area, and the appropriate range from the start point may continue the dose to the head area, and then start decreasing. As described above, when specifying by the assumption without precisely specifying the head region, the starting point of the head adjacent region is similarly specified by the assumption.

When the amount of accumulated light is gradually decreased from the dose to the head region to 0, the rate of decrease in the amount of accumulated light per second in the UVA of the ultraviolet ray is preferably 1500 mJ / cm 2 · sec or less, more preferably 1000 mJ / cm 2 · sec or less. desirable. If the reduction rate of the accumulated light amount is too high, even if the accumulated light amount is gradually decreased, the effect cannot be sufficiently obtained, and at the boundary between the hardened portion (head region A) and the uncured portion, the film thickness difference or the internal stress is reduced. The resin peeling may occur due to the distortion. Although the head adjoining area width can be appropriately determined by adjusting the reduction rate of the irradiation amount to the head area and the accumulated light amount, it is usually about 0.3 to 500 cm.

In a 1st hardening process, in addition to the head area | region A of a coating layer, it is preferable to irradiate an active energy ray also to a tail area | region, and to harden this. This is because the rear region is also a portion where the film thickness of the coating layer is remarkably thick, and resin peeling is concentrated. By curing the trailing region in advance, it is possible to effectively prevent the resin residue from remaining in the mold. In particular, preventing resin residues due to the coating layer trailing region is very advantageous in preventing continuous defects in manufacturing the optical film of the next lot (using the next base film).

Irradiation of the active energy ray to the coating layer tail region is specifically, with reference to FIG. 2, when the tail region B of the coating layer 12 is just below the active energy ray irradiation apparatus 10, Alternatively, the active energy ray irradiation device 10 is set to the ON state (the state in which the active energy ray is irradiated) immediately before passing immediately below, and the state is maintained until the trailing region B passes through.

For the same reason as in the case of the head region A, the dose to the trailing region is the amount of accumulated light in the UVA of the ultraviolet rays when the active energy ray is the ultraviolet ray, preferably 70 mJ / cm 2 or more and 400 mJ / cm 2 or less. More preferably, they are 100 mJ / cm <2> or more and 250 mJ / cm <2> or less.

Prior to irradiation of the active energy ray to the coating layer trailing region B, for the same reason as in the case of the leading region A, the active energy ray is moved to the trailing edge region, and the amount of accumulated light from 0 at the start point of the trailing edge region. It is preferable to irradiate so that it may increase gradually along the conveyance direction of a film until it becomes the irradiation amount in a tail region. The trailing-adjacent region is an area | region adjacent to a trailing-region area here, until it irradiates an active energy ray so that it may gradually increase from the said irradiation amount 0, and may become the irradiation amount in a trailing area | region. The irradiation dose may be increased so as to reach the dose to the trailing region from the end point of the trailing edge region which is in contact with the trailing region, and the dose to the trailing region is reached at a suitable point closer to the trailing point, and the dose to the trailing region from the point to the end point. You may continue. As described above, when specifying by the assumption without precisely specifying the trailing region, the end point of the trailing adjacent region is similarly specified by the assumption.

When the accumulated light amount is gradually increased from 0 to the irradiation amount in the trailing region, the increase rate of the accumulated light amount per second in the UVA of ultraviolet light is 1500 mJ / cm 2 · second for the same reason as in the case of the head region A. It is preferable that it is the following, and it is more preferable that it is 1000 mJ / cm <2> * sec or less. The rear adjacent region width can be appropriately determined by adjusting the increase rate of the irradiation amount and the accumulated light quantity in the rear region, but is usually about 0.3 to 500 cm.

The method of gradually changing (decreasing or increasing) the accumulated light amount is not particularly limited, and for example, a method of gradually changing the voltage applied to the active energy ray irradiation device 10; A method of accommodating the active energy ray irradiation device 10 with a lamp box having an irradiation window provided with an open shutter, and changing the opening and closing speed of the shutter; As the shutter, a method of using a comb-type filter having a plurality of thin comb teeth whose width gradually narrows in the shutter opening and closing direction (therefore, when the shutter is closed / opened, the accumulated light amount gradually decreases according to the opening area between the comb teeth). / Increase); As the shutter, a method in which a photosensitive filter having a different photosensitive rate is arranged so as to change the photosensitive rate gradually (for example, when using a shutter arranged so that the photosensitive rate gradually increases from the end of the shutter, the shutter may be closed / opened). When accumulated light is gradually reduced / increased according to the filter's photosensitivity rate; Or the method which combined any two or more of the above is mentioned.

[3] second curing processes

This process hardens on a base film by irradiating an active energy ray to a coating layer from the base film side, and hardening a coating layer in the state which pressed the surface of the mold which has a predetermined surface shape to the surface of a coating layer. It is a process of forming the resin layer. As a result, the coating layer is cured, and the surface shape of the mold is transferred to the coating layer surface.

As shown in FIG. 1, this process is crimped | bonded with the nip roll 13 etc. to the surface of the coating layer 12 of the laminated body of the base film 11 and the coating layer 12 which passed through the 1st hardening process. By using the device, the roll-shaped mold 14 is pressed, and in this state, the active energy ray is irradiated onto the coating layer 12 from the base film 11 side by using the active energy ray irradiation device 15. The coating layer 12 can be hardened. The use of a nip roll is effective in preventing the mixing of bubbles between the coating layer and the mold. As the active energy ray irradiation device, one device or a plurality of devices can be used.

After irradiation of an active energy ray, a laminated body peels from the mold 14 using the nip roll 16 of an exit side as a point. The optical film which consists of the obtained base film and hardened resin layer is normally wound up by the film winding-up apparatus 34. FIG. At this time, in order to protect a resin layer, you may wind up while sticking the protective film which consists of polyethylene terephthalate, polyethylene, etc. to the resin layer surface through the adhesive layer which has removability. In addition, the shape of the mold to be used is not limited to what is roll shape.

After peeling from a mold, you may perform further active energy ray irradiation. Moreover, instead of performing active energy ray irradiation in the state pressed on the mold, after peeling a base film with an uncured coating layer from a mold, you may irradiate and harden an active energy ray.

The kind and the light source of the active energy ray used in this step are the same as in the first curing step. When the active energy ray is an ultraviolet ray, the accumulated light amount in the UVA of the ultraviolet ray is preferably 40 mJ / cm 2 or more and 2000 mJ / cm 2 or less, and more preferably 70 mJ / cm 2 or more and 1800 mJ / cm 2 or less. When accumulated light amount is less than 40 mJ / cm <2>, hardening of a coating layer becomes inadequate, the hardness of the resin layer obtained becomes low, or uncured resin adheres to a guide roll etc., and there exists a tendency which causes process contamination. Moreover, when accumulated light amount exceeds 2000 mJ / cm <2>, the base film may shrink | contract by the heat radiated | emitted from an ultraviolet irradiation apparatus and may cause wrinkles.

The mold used in this step is for imparting a desired shape to the surface of the resin layer formed on the base film, and has a surface shape composed of the transfer structure of the desired shape. The surface shape of the mold can be transferred to the resin layer surface by curing the coating layer while pressing the surface shape on the surface of the coating layer to the surface of the coating layer. As a mold, the mold (for example, mirror surface roll) which has a surface which consists of mirror surfaces, and the mold (for example, emboss roll) which has an uneven surface are mentioned.

In the case where the mold has an uneven surface, the uneven pattern may be a regular pattern, or may be a random pattern or a pseudo-random pattern on which one or more types of random patterns of a specific size are laid out on the front surface. It is preferable that it is a random pattern or a pseudo random pattern from the point which prevents a reflected image from coloring in rainbow color by interference of reflected light.

The external shape of the mold is not particularly limited, and may be a flat plate or a cylindrical or cylindrical roll, but is preferably a cylindrical or cylindrical mold such as a mirror roll or an emboss roll in terms of continuous productivity. In this case, a predetermined surface shape is formed on the side of the cylindrical or cylindrical mold.

The material of the base material of the mold is not particularly limited and can be appropriately selected from metals, glass, carbon, resins, or composites thereof, but metals are preferred in view of workability and the like. Preferred metal materials include aluminum, iron, or an alloy mainly composed of aluminum or iron from the viewpoint of cost.

As a method of obtaining a mold, for example, a method of polishing a substrate, sandblasting, and then electroless nickel plating (JP2006-53371-A); Copper plating or nickel plating on the substrate, followed by polishing, sandblasting, and then chromium plating (JP2007-187952-A); Copper plating or nickel plating, followed by polishing, sandblasting, etching or copper plating, and then chromium plating (JP2007-237541-A); After copper plating or nickel plating on the surface of a base material, it grind | polishs, the photosensitive resin film is apply | coated and formed on the polished surface, and it exposes and develops a pattern on the said photosensitive resin film, and develops, using the developed photosensitive resin film as a mask. A method of etching to remove the photosensitive resin film, further performing etching to blunt the uneven surface, and then performing chromium plating on the formed uneven surface; And a method (WO2007 / 077892-A) for cutting a substrate to be cast by a cutting tool using a machine tool such as a lathe.

The surface irregularities of the mold formed of a random pattern or a pseudo random pattern may be, for example, by an FM screen method, a DLDS (Dynamic Low-Discrepancy Sequence) method, a method using a microphase separation pattern of a block copolymer, or a bandpass filter method. The produced random pattern can be formed by exposing and developing on the photosensitive resin film, and performing an etching process using the developed photosensitive resin film as a mask.

The optical film of this invention obtained as mentioned above is applied suitably to image display apparatuses, such as a liquid crystal display device, for example, the hard-coat layer for preventing the resin layer on a base film from damage resulting from various external forces. Phosphorous hard coat film (it may contain translucent microparticles | fine-particles); A viewer-side light-diffusion film which is a light-diffusion layer (containing light-transmitting fine particles as a light-diffusing agent) for diffusing light emitted from the liquid crystal cell to improve the viewing angle; Anti-glare film which is a glare-proof layer (it may contain translucent microparticles | fine-particles) which has a surface unevenness | corrugation for preventing a resin layer from reflecting or flashing external light; The resin layer may be a back side light diffusion film (diffusion plate) or the like which is a light diffusion layer (containing light-transmitting fine particles as a light diffusing agent) for diffusing light incident on the liquid crystal cell to prevent moire caused by the backlight unit. have. A hard coat film, a viewer side light-diffusion film, and an anti-glare film are normally used by bonding to a polarizing film as a viewer side protective film of a viewer side polarizing plate (that is, arrange | positioned on the surface of an image display apparatus). A back side light-diffusion film is normally bonded to a polarizing film as a backlight side protective film of a backlight side polarizing plate.

The optical film of this invention may further be equipped with the antireflection layer laminated | stacked on the resin layer (surface on the opposite side to a base film). The antireflection layer is formed in order to make the reflectance extremely low, and by forming the antireflection layer, reflection on the display screen can be prevented. Examples of the antireflection layer include a low refractive index layer made of a material lower than the refractive index of the resin layer; The laminated structure of the high refractive index layer which consists of a material higher than the refractive index of a resin layer, and the low refractive index layer which consists of a material lower than the refractive index of this high refractive index layer, etc. are mentioned. There is no restriction | limiting in particular in the lamination | stacking method of an antireflection layer, You may laminate | stack directly on a resin layer, You may prepare separately what laminated | stacked the antireflection layer on the base film previously, and may join on a resin layer using an adhesive etc.

<Polarizer>

The polarizing plate of this invention is equipped with a polarizing film and the optical film obtained by the above-mentioned manufacturing method laminated | stacked on the said polarizing film so that a base film side may oppose the said polarizing film. The polarizing film has a function of taking out linearly polarized light from incident light, and the kind thereof is not particularly limited. As an example of a preferable polarizing film, the polarizing film in which the dichroic dye is adsorption-oriented to polyvinyl alcohol-type resin is mentioned. As polyvinyl alcohol-type resin, in addition to the polyvinyl alcohol which is a saponified substance of vinyl acetate, the partially formalized polyvinyl alcohol, the saponified substance of an ethylene / vinyl acetate copolymer, etc. are mentioned. As a dichroic dye, iodine or a dichroic organic dye is used. Moreover, the polyene oriented film of the dehydration process of polyvinyl alcohol, and the dehydrochlorination process of polyvinyl chloride can also be a polarizing film. The thickness of a polarizing film is about 5-80 micrometers normally.

The polarizing plate of this invention may laminate | stack the optical film which concerns on this invention on one side or both surfaces (usually one side) of the said polarizing film, and laminates a transparent protective layer on one side of the said polarizing film, What laminated | stacked the optical film which concerns on this invention may be sufficient.

At this time, the optical film also has a function as a transparent protective layer (protective film) of the polarizing film. A transparent protective layer can be formed on a polarizing film by the method of bonding a transparent resin film using an adhesive agent, etc., the method of apply | coating a transparent resin containing coating liquid, etc. Similarly, the optical film which concerns on this invention can be bonded to a polarizing film using an adhesive agent etc ..

It is preferable that the transparent resin film used as a transparent protective layer is excellent in transparency, mechanical strength, thermal stability, water shielding property, etc., For example, such as a triacetyl cellulose, a diacetyl cellulose, a cellulose acetate propionate, etc. Cellulose resins such as cellulose acetate; Polycarbonate resin; (Meth) acrylic resins such as polyacrylate and polymethyl methacrylate; Polyester-based resins such as polyethylene terephthalate and polyethylene naphthalate; Chain polyolefin resins such as polyethylene and polypropylene; Cyclic polyolefin resins; Styrene type resin; Polysulfones; Polyether sulfone; The film which consists of polyvinyl chloride resin etc. is illustrated. These transparent resin films may be optically isotropic, and may have optically anisotropy for the purpose of compensating the viewing angle when inserted into the image display device.

<Image Display Device>

The image display apparatus of this invention combines the polarizing plate of the said this invention, and the image display element which illuminates various information on a screen. The kind of the image display apparatus of this invention is not specifically limited, In addition to the liquid crystal display (LCD) using a liquid crystal panel, a cathode ray tube (cathode ray tube: CRT) display, a plasma display (PDP), an electrolytic emission display (FED), and a surface conduction type Electron emission element displays (SED), organic EL displays, laser displays, screens of projector televisions, and the like.

For example, when arrange | positioning the polarizing plate of this invention on a liquid crystal cell, and manufacturing a liquid crystal panel, a polarizing plate is arrange | positioned on a liquid crystal cell so that the polarizing film may become the liquid crystal cell side (outside the resin layer). The same applies to other image display apparatuses. An optical film may be arrange | positioned at the visual recognition side of an image display element, may be arrange | positioned at the backlight side, or may be arrange | positioned at both. When arrange | positioning an optical film at the visual recognition side, an optical film can function as a hard-coat film, a light-diffusion film, an anti-glare film, an antireflection film, etc. On the other hand, when an optical film is arrange | positioned at the backlight side, an optical film can function as a light-diffusion film (diffusion plate) etc. which diffuse the light which injects into a liquid crystal cell, and prevents moire.

Example

Hereinafter, although an Example is given and this invention is demonstrated in detail, this invention is not limited to these Examples.

&Lt; Example 1 >

The following components were mixed and the ultraviolet curable coating liquid was prepared.

UV-curable resin: 60 parts by weight of pentaerythritol triacrylate and 40 parts by weight of polyfunctional urethane acrylate (reaction product of hexamethylene diisocyanate and pentaerythritol triacrylate)

ㆍ Photopolymerization initiator: 5 parts by weight of "Lucirine TPO" (manufactured by BASF, Chemical name: 2,4,6-trimethylbenzoyldiphenylphosphine oxide),

Diluent solvent: 100 parts by weight of ethyl acetate.

The coating solution was coated on a triacetyl cellulose (TAC) film (base film) having a thickness of 80 μm with a gravure coater to form a coating layer, thereby obtaining a laminate of the base film and the coating layer [coating step]. After drying the obtained laminated body with a drying furnace, the accumulated amount of accumulated light in UVA was 1st predetermined value (front area | region) using the ultraviolet irradiation device provided with the comb-type filter which has a plurality of fine comb teeth which become narrow gradually in the opening-and-closing direction. The ultraviolet rays are irradiated from the coating layer side to the leading region of the coating layer so as to gradually decrease from 0 to the irradiation amount), and the coating is performed so that the amount of accumulated light in the UVA gradually increases from 0 to the second predetermined value (the amount of irradiation to the trailing region). Ultraviolet rays were irradiated to the trailing region of the layer from the coating layer side [first curing step]. In the present embodiment, the first and second predetermined values are 100 mJ / cm 2, and the decrease rate (irradiation to the leading region) and the increase rate (irradiation to the tail region) of the accumulated light quantity per second in the UVA of the ultraviolet light are described below. In general, the reduction rate and the increase rate are collectively referred to as the change rate.

Next, the chrome plating roll polished so that the surface might become a mirror surface was pressed and stuck to the coating layer surface of the laminated body which passed through the 1st hardening process using the nip roll. In this state, ultraviolet-ray was irradiated and hardened the coating layer so that the maximum illuminance in UVA might be 700 mW / cm <2> and accumulated light amount in UVA to 300 mJ / cm <2> from a base film side [2nd hardening process]. Thereafter, the laminate was peeled from the chrome plating roll to obtain an optical film having an average film thickness of 10 μm of a resin layer made of a cured product of an ultraviolet curable resin.

<Examples 2-5>

The optical film was produced like Example 1 except having changed the 1st and 2nd predetermined value and the change rate of the accumulated light quantity per second in UVA of ultraviolet-ray as shown in Table 1. In addition, in Example 4, the comb filter was not used.

&Lt; Comparative Example 1 &

Except not having performed the 1st hardening process, it carried out similarly to Example 1, and produced the optical film.

(Evaluation of resin residue)

The surface of the chromium plating roll after producing each Example and the comparative example was observed, 1) Coating layer edge part (lead end part and tail end part), and 2) Hardening part (head area | region and tail area | region) in a 1st hardening process ) And the presence or absence of a resin residue at a position corresponding to the boundary of the uncured portion, and the degree of the resin residue was evaluated according to the following criteria.

(Circle): At the position of said 1) and 2), resin residue is not seen over the full width direction.

(Triangle | delta): Although resin residue is seen in the position of said 1) or 2), the range is 1/3 or less of full width.

X: Resin residue is seen in the position of said 1) or 2), and the range exceeds 1/3 of full width.

Figure pct00001

In addition, the resin residue which a little generate | occur | produced in Example 3 and the resin residue of the comparative example 1 generate | occur | produced in the position of said 1). In addition, the resin residue which generate | occur | produced in Example 4 and 5 generate | occur | produced in the position of said 2).

As shown in Table 1, it can be seen that the resin residue can be reduced by performing the first curing step of curing the end region of the coating layer in advance. Moreover, it turns out that resin residue can be prevented effectively by making the accumulated light quantity of the ultraviolet-ray in a 1st hardening process, and its change rate into a predetermined range.

10, 15: active energy ray irradiation apparatus 11: base film
12: Coating layer 13, 16: Nip roll
14: mold 31: film unwinding device
32: coating apparatus 33: drying furnace
34: film winding device

Claims (10)

Coating process which coats the coating liquid containing active energy ray curable resin on a base film conveyed continuously, and forms a coating layer,
A first curing step of irradiating an active energy ray to the head region of the coating layer from the coating layer side;
2nd hardening process which irradiates an active energy ray to the said coating layer from the said base film side in the state which pressed the surface of the mold to the surface of the said coating layer.
Method for producing an optical film comprising a. The head adjoining area according to claim 1, wherein in the head adjoining area in contact with the head area irradiated with an active energy ray, the amount of accumulated light in the head adjoining area is gradually decreased from the amount of irradiation to the head area, and the head adjoining area. How to investigate to be zero at the end of. The method according to claim 1 or 2, wherein the active energy ray is ultraviolet light,
The irradiation amount of the active energy ray to the said head region in a said 1st hardening process is 70 mJ / cm <2> or more and 400 mJ / cm <2> or less by the accumulated light quantity in the UVA of the said ultraviolet-ray. The method according to claim 2 or 3, wherein the active energy ray is ultraviolet light,
The reduction rate of the accumulated light amount in UVA of the said ultraviolet-ray is 1500 mJ / cm <2> / sec or less. The method according to any one of claims 1 to 4, wherein in the trailing region, an active energy ray is irradiated to the trailing region from the coating layer side prior to the second curing step. The trailing edge region of claim 5, wherein in the trailing edge region in contact with the trailing edge region, prior to irradiation of the active energy ray to the trailing edge region, the active energy ray is applied to the trailing edge region, and the accumulated light amount is zero at the start point of the trailing edge region. Irradiating gradually to the amount of irradiation to the trailing area. The method according to claim 5 or 6, wherein the active energy ray is ultraviolet light,
The irradiation amount of the active energy ray to the said tail region is 70 mJ / cm <2> or more and 400 mJ / cm <2> or less by the accumulated light quantity in the UVA of the said ultraviolet-ray. The method according to claim 6 or 7, wherein the active energy ray is ultraviolet light,
The increase rate of the accumulated light amount in UVA of the said ultraviolet-ray is 1500 mJ / cm <2> / sec or less. With a polarizing film,
The optical film manufactured by the method in any one of Claims 1-6 laminated | stacked on the said polarizing film so that a base film side may oppose the said polarizing film.
Polarizing plate having a. The polarizing plate of Claim 9, and the image display element are provided,
The said polarizing plate is arrange | positioned on the said image display element so that the polarizing film may become the said image display element side.
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