TWI445995B - Anti-glare film, anti-glare film and portrait display device - Google Patents

Description

Anti-glare film, anti-glare polarizing plate and image display device

The present invention relates to an anti-glare film which is low in haze while exhibiting excellent anti-glare performance, and an image display device including the anti-glare film.

The present invention relates to the case of exhibiting excellent anti-glare performance without blushing, and when applied to an image display device, it does not cause glare, and achieves high contrast and gives good visibility. An anti-glare film and an anti-glare polarizing plate and an image display device including the anti-glare film.

An image display device such as a liquid crystal display or a plasma display panel, a Brown tube (Cathode tube: CRT) display, or an organic electroluminescence (EL) display, if the display surface is reflected with external light, the visibility is Significantly damaged. In order to prevent such external light from entering, it is a video camera or a personal computer that is used for image quality, a video camera used outside the house where the outside light is strong, a digital camera, and a mobile phone that uses reflected light for display. From the previous point, a film layer for preventing the reflection of external light is provided on the surface of the image display device. The film layer can be roughly classified into a film which is coated with a non-reflective film by interference of an optical multilayer film, and which diffuses the incident light by blurring the surface and forms an image of the reflected image. A film made of an anti-glare treatment. Among them, the former non-reflective film, because it is necessary to form a uniform film thickness of the multilayer film Therefore, the cost system becomes higher. On the other hand, the latter anti-glare film is widely used in large-sized personal computers or screens because it can be manufactured at a relatively low cost.

Such an anti-glare film is used in the prior art, for example, by coating a resin solution in which a filler is dispersed on a substrate sheet, and exposing the filler from the surface of the coating film by adjusting the thickness of the coating film. It is produced by a method of forming random irregularities on a sheet or the like. However, such an anti-glare film produced by dispersing a filler may have an influence on the arrangement or shape of the concavities and convexities depending on the dispersion state or the coating state of the filler in the resin solution, and thus it is difficult to obtain The unevenness in the state expected is that a sufficient anti-glare effect cannot be obtained in a case where the haze is low. Further, when such an anti-glare film of the prior art is disposed on the surface of the image display device, the entire surface of the display surface is whitened by the diffused light, and the display is turbid, that is, the so-called whitening occurs. Happening.

In addition, with the recent refinement of the image display device, the surface unevenness of the pixels of the image display device and the anti-glare film interfere with each other, and as a result, a luminance distribution is generated, which makes it difficult to visually recognize, that is, it is easy A so-called glare phenomenon occurs. In order to solve the glare phenomenon, although it is attempted to provide a refractive index difference between the adhesive resin and the dispersion filler to diffuse light, when such an anti-glare film is applied to an image display device, since the light is diffused, it is black. The brightness is increased when displayed, and as a result, the contrast is reduced and the visibility is significantly reduced.

On the other hand, it has been attempted to achieve anti-glare property by not including the filler but only by the fine unevenness formed at the surface of the transparent resin layer. . For example, Japanese Laid-Open Patent Publication No. 2002-189106 (Patent Document 1) discloses that an ionizing radiation curable resin is held between a embossing mold and a transparent resin film, and in this state, the ionizing radiation hardening is performed. The resin is hardened, whereby three-dimensional 10-point average roughness is formed, and the average distance between adjacent convex portions on the three-dimensional thickness reference surface respectively satisfies a minute value of a specific value, and then The ionizing radiation-curable resin layer on which the irregularities are formed is provided on the transparent resin film to obtain an anti-glare film. In this document, it is described that it is preferable to use a cylinder having chrome plating on the surface of iron, and to form a concave-convex surface for embossing by a sandblasting method or a bead method. Further, it is described that, in order to improve the durability during use, it is preferable to apply chrome plating or the like before use, and it is possible to achieve a dura mater. And corrosion prevention.

In the method for producing such an embossing cylinder, since sandblasting or beading is performed on the chromium plating having high hardness, it is difficult to form the unevenness, and it is difficult to precisely control the shape of the formed unevenness. Further, as described in Japanese Laid-Open Patent Publication No. 2004-29672 (Patent Document 2), in general, chrome plating depends on the material to be the base and the shape thereof, so that the surface becomes rough and is blasted by sandblasting. On the formed irregularities, fine cracking due to chromium plating occurs, and therefore, it is difficult to know what kind of irregularities are to be formed. Further, since there is a fine chipping due to chrome plating, the anti-glare film finally obtained may have a diffusion property which changes in an undesired direction.

As a method for producing a film having irregularities on its surface For example, Japanese Laid-Open Patent Publication No. 2004-29240 (Patent Document 3) or JP-A-2004-90187 (Patent Document 4). In the former literature, a method of making an embossing cylinder by a bead blasting method is disclosed, and in the latter literature, it is revealed that a metal plating layer is formed on the surface of a embossing cylinder, and metal plating is performed. The surface of the layer is subjected to mirror polishing, and the surface of the metal plating after mirror polishing is used, and the ceramic bead is used to apply the blasting process, and further, the peening process is performed according to the need. The method of embossing the drum.

In the state in which the blasting treatment is applied to the surface of the embossing cylinder, the distribution of the diameter of the blasting particles is caused by the distribution of the particle diameter of the blasting particles, and at the same time, the depth of the pit obtained by sand blasting is controlled. In order to be difficult, there is a problem that it is difficult to obtain a concave-convex shape excellent in anti-glare function with good reproducibility.

Japanese Patent Laid-Open Publication No. Hei. No. 2006-53371 (Patent Document 5) discloses a method of projecting fine particles on the surface of a metal to be polished to form irregularities, and applying an electric field thereto. Nickel plating was used to form a mold, and the uneven surface of the mold was transferred onto a transparent resin film to produce an anti-glare film having low haze and excellent anti-glare properties.

In addition, JP-A-2003-248101 (Patent Document 6) or JP-A-2004-126495 (Patent Document 7) is known as a document for specifying the intensity of the transmitted light of the anti-glare film. In the former document, an anti-glare anti-reflection film is disclosed as a film having an anti-glare hard coating layer on a transparent support, when light is incident from the side of the transparent support, ratio (I ₅ / I _0), Department of less than 3.5%, with respect to the straight light quantity (I ₀₎ the light transmission of the diffused to tilt the light amount at the direction of 5∘ of (I ₅₎ being transmitted through the The ratio (I ₂₀ /I ₀ ) of the amount of light (I ₂₀ ) diffused in the direction inclined by 20 , in the amount of direct light (I ₀ ) in the light is 0.1% or less. In the latter literature, it is revealed that the diffusion angle of the maximum value of the diffused light intensity is 0.1 to 10 Å, and the total light transmittance is 70 to 100% of the anti-glare film. Even with the anti-glare film disclosed in the above documents, it is difficult to maintain high contrast particularly in the case of being suitable for use in a high-definition image display device.

The present invention provides a method for preventing the deterioration of visibility due to whitening while exhibiting excellent anti-glare performance, and does not cause glare when disposed on the surface of a high-definition image display device. In this case, an anti-glare film having a high contrast is realized, and an anti-glare polarizing plate and an image display device to which the anti-glare film is applied are provided.

The present inventors have made an effort to solve the above problems, and as a result, it has been found that when an anti-glare film having an anti-glare layer having a fine uneven surface is formed on a transparent support, when the light is from When the transparent support side is incident at an incident angle of 20 ,, the relative diffused light intensity T(20) at the normal direction of the anti-glare layer side is set to a specific value, and when the light is incident from the transparent support side, the incident angle is obtained. At 30 ∘, when the relative diffused light intensity T (30) at the normal direction of the anti-glare layer is set to a specific value, it is suitable for use in an image display device, in addition to being able to sufficiently prevent glare. It also becomes almost impossible to reduce. Further, it has been found that in the anti-glare film, when light is incident from the side of the anti-glare layer at the incident angle 30, if the reflection angle is 30 ∘ The reflectance R (30), the reflectance R (40) of the reflection angle 40 以及, and the reflectance R (50) of the reflection angle 50 成为 are specific values, respectively, and exhibit excellent anti-glare properties and effectively prevent pan-inhibition. White effect is more effective. The present invention has been completed based on such knowledge and further various review.

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

In the anti-glare film, it is generally preferred that when the light is incident from the anti-glare layer side at an incident angle of 30 Å, the reflectance R (30) of the reflection angle 30 系 is 0.05% or more and 2% or less. The reflectance R (40) of the reflection angle of 40 Å is 0.0001% or more and 0.005% or less, and the reflectance R (50) of the reflection angle of 50 Å is 0.00001% or more and 0.0005% or less.

Further, it is generally preferred that when the light is incident perpendicularly to the antiglare film, the surface haze is 0.1% or more and 5% or less, and the total haze is 5% or more and 25% or less.

The anti-glare film can be set to be incident on light when three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm in the dark portion and the bright portion are used. The sum of the reflection sharpness measured at the angle of 45 系 is _40% or less.

Further, it is preferable that the antiglare film has an arithmetic mean height Pa of 0.05 μm or more and 0.2 μm or less at a cross-sectional curve of the uneven surface constituting the antiglare layer, and the maximum sectional height Pt is 0.2 μm. Above lμm or less, the average length PSm is 15 μm or more and 30 μm or less.

Further, it is preferable that the uneven surface constituting the antiglare layer is provided in a region of 200 μm × 200 μm, and has 50 or more convex portions of 100 or less, and the apex of the convex portion is used as a mother point. When the surface is subjected to voronoi tessellation, the average area of the polygonal formed is 100 μm ² or more and 1000 μm ² or less.

The antiglare layer in the antiglare film is preferably formed by transferring through a mold having a concave-convex surface to form surface unevenness. In addition, it is preferable that 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, and the difference in refractive index between the binder and the binder resin is 0.01 or more and 0.06 or less. The fine particles are 10 to 100 parts by weight, and further, the fine particles are completely buried in the anti-glare layer, and the fine particles do not affect the uneven shape of the surface.

In this anti-glare film, a low-reflection film can be formed at the uneven surface of the anti-glare layer.

The anti-glare film of the present invention can be combined with a polarizing element made of a polyvinyl alcohol-based resin to form an anti-glare polarizing plate. Specifically, the anti-glare polarizing plate has a structure in which the transparent support side of the anti-glare film is bonded to a polarizing element.

Moreover, the anti-glare film of the present invention or an anti-glare polarizing plate can be combined with an image display element such as a liquid crystal display element or a plasma display panel, and can be used as an image display device. Here, the image display device according to the present invention is provided with the anti-glare film described above or an anti-glare polarizing plate and an image display means, and the anti-glare film or the anti-glare polarizing plate is It is placed on the side of the image display device.

Next, a suitable embodiment of the present invention will be described in detail. The anti-glare film of the present invention is formed by forming an anti-glare layer having a fine uneven surface on a transparent support, and is characterized in that when light is incident from the transparent support side at an incident angle of 20 ,, The relative diffused light intensity T(20) observed in the normal direction of the anti-glare layer is a value of 0.0001% or more and 0.0005% or less. When light is incident from the transparent support side at an incident angle of 30 ,, the defense is prevented. The relative diffused light intensity T(30) observed in the normal direction of the glare layer is 0.00004% or more and 0.00025% or less.

Further, in order to exhibit excellent anti-glare performance and to effectively suppress whitening, it is generally desirable to have a reflection angle of 30 when the light is incident from the side of the anti-glare layer at an incident angle of 30 ∘. The reflectance R (30) is 0.05% or more and 2% or less, the reflectance R (40) of the reflection angle of 40 系 is 0.0001% or more and 0.005% or less, and the reflectance R (50) of the reflection angle of 50 系 is 0.00001%. Above 0.0005%.

[relative diffused light intensity] First, when light is incident at an incident angle of 20 从 from the side of the transparent support, and when light is incident at an incident angle of 30 ,, the relative diffused light at the normal direction of the anti-glare layer side The strengths T(20) and T(30) are explained.

Fig. 1 is a view showing an incident direction of light when light is incident from the transparent support side (opposite to the uneven surface) and the intensity of the diffused light at the normal direction of the anti-glare layer is measured. A perspective view showing a pattern display by the direction of the measured intensity of the diffused light. Referring to this figure, there is an angle from the normal line 12 at the transparent support side of the anti-glare film 11. The light 13 incident (referred to as the incident angle) is measured by the intensity of the diffused light 14 transmitted through the normal direction 12 of the anti-glare layer side, and the intensity of the transmitted diffused light is divided by the light intensity of the light source. The value is set to the relative diffused light intensity T ( ). That is, when the incident light 13 is incident on the transparent support side of the anti-glare film 11 at an angle of 20 离开 from the normal line, the light 14 is observed at the normal direction 12 of the anti-glare layer side. The value obtained by dividing the intensity by the light intensity of the light source is T (20), and when the incident light 13 is incident on the transparent support side of the anti-glare film 11 at an angle of 30 离开 from the normal line, it will be prevented. The value of the intensity of the emitted light 14 observed at 12 in the normal direction of the glare layer divided by the light intensity of the light source is T (30).

When the relative diffused light intensity T(20) at the time of 20 ∘ injection exceeds 0.0005%, when the anti-glare film is applied to an image display device, the brightness is increased due to the diffused light. And the contrast is reduced, so it is not ideal. Further, when the relative diffused light intensity T(20) at the time of 20 ∘ injection is less than 0.0001%, the diffusion effect is low. When it is applied to a high-definition image display device, it is glaring, which is also undesirable. Similarly, when the relative diffused light intensity T (30) at the time of 30 ∘ injection exceeds 0.00025%, when the anti-glare film is applied to the image display device, the black light is also displayed due to the diffused light. The brightness rises and the contrast is lowered, so it is not ideal. Further, when the relative diffused light intensity T(30) at the time of 30 ∘ is less than 0.00004%, the diffusion effect is also low, and when applied to a high-definition image display device, glare occurs. Therefore, it is not ideal. In particular, when the anti-glare film is applied to a non-self-luminous type liquid crystal display, the effect of brightness increase due to diffusion due to light leakage during black display is large, and therefore, the relative diffused light intensity is When T(20) and T(30) exceed the values specified in the present invention, the contrast ratio is remarkably lowered to be a result of loss of visibility.

For example, the above-mentioned patent document 6 (JP-A-2003-248101) or Patent Document 7 (Japanese Laid-Open Patent Publication No. 2004-126495) is hereby incorporated by reference. However, in both of the documents, the diffusion characteristics defined in the present invention are different, and when applied to an image display device, it cannot be said that a high contrast can be sufficiently achieved and a glare is suppressed.

2 is an incident angle of the transparent support body side of the anti-glare film 11 in FIG. The relative diffused light intensity (logarithmic scale) measured relative to the angle of incidence An example of a chart for drawing. There is also a graph showing the relationship between the incident angle and the relative diffused light intensity, or the relative diffused light intensity at each incident angle from which it can be read, which is called a transmission-scattering distribution. As shown in this graph, the relative diffused light intensity exhibits a peak at an incident angle of 0 ,, and if the angle of the incident light 13 from the normal direction is shifted, the tendency of the diffused light intensity decreases. . Further, the positive (+) and negative (-) angles of the incident angle are centered on the normal direction (0 ∘), and are incident through the surface 19 including the direction 13 of the incident light and the normal 12 The slope of the light is set by the person. Therefore, the diffusion distribution is usually centered on the incident angle 0 , and is bilaterally symmetric. In the example of the transmission diffusion distribution shown in FIG. 2, the relative diffused light intensity T(0) at 0 ∘ incidence is about 30% and shows a peak, and when 20 ∘ is incident, the relative diffused light intensity T (20) is about 0.0002%, and the relative diffused light intensity T(30) at 30 ∘ is about 0.00004%.

When measuring the relative diffused light intensity of the anti-glare film, it is necessary to measure the relative diffused light intensity of 0.001% or less with good precision. Here, it is effective to use a detector having a wide dynamic range. As such a detector, for example, a commercially available optical power meter or the like can be used, and an aperture can be provided in front of the detector of the optical power meter, and the angle at which the anti-glare film is made can be 20 ∘. A variable angle photometer was used for the measurement.

For the incident light, a visible light of 380 to 780 mm can be used as the measuring light source, and the light emitted from a light source such as a halogen lamp can be collimated, or a laser or the like can be used. The color source is parallel and the parallelism is high. Further, in order to prevent the film from being bent, it is preferable to use an optically transparent adhesive and bond the uneven surface to the glass substrate so as to have a surface.

[30 反射 reflectivity at the time of injection] Next, the reflectance at each angle when light is incident at an incident angle of 30 Å from the side of the anti-glare layer will be described. Fig. 3 is a perspective view schematically showing an incident direction and a reflection direction of light from the side of the anti-glare layer of the anti-glare film in which the reflectance is obtained. Referring to this figure, the direction of the reflection angle 30 、, that is, the direction of the regular reflection 16 with respect to the incident light 15 incident from the anti-glare layer side of the anti-glare film 11 from the angle of the normal line 1230 16 The reflectance of the reflected light (that is, the regular reflectance) is set to R (30). Further, the reflected light at an arbitrary reflection angle θ is denoted by reference numeral 17, and the directions 16 and 17 of the reflected light when the reflectance is measured are set to be in the direction 15 including the incident light and the normal. Inside the face 19 of 12. Further, the reflectance in the direction toward the reflection angle 40 设为 is R (40), and the reflectance in the direction toward the reflection angle 50 设为 is R (50).

In the anti-glare film of the present invention, the reflectance in the direction of the reflection angle of 30 相对 with respect to the incident light of 30 入射, that is, the regular reflectance R (30) is set to be 0.05% or more and 2% or less. Ideal. Further, the reflectance R (40) in the direction of the reflection angle of 40 Å is preferably 0.0001% or more and 0.005% or less, and the reflectance in the direction of the reflection angle of 50 Å is R (50), which is 0.00001% or more and 0.0005%. The following are ideal.

If the regular reflectance R (30) exceeds 2%, a sufficient anti-glare function cannot be obtained, and the visibility is lowered. On the other hand, if the regular reflectance R (30) is too small, whitening tends to occur, so that it is preferably 0.05% or more. The positive reflectance R (30) is set to 1.5% It is more preferable to set it to 0.7% or less. In addition, when R (40) exceeds 0.005% and R (50) exceeds 0.0005%, whitening occurs in the antiglare film, and visibility is lowered. That is, for example, even if the anti-glare film is placed at the forefront of the display device, the display surface is black-displayed, and the light from the surroundings is picked up, and the entire display surface is changed. The tendency of the whitening state of white. Therefore, it is desirable that R (40) and R (50) are not excessively large. On the other hand, if the reflectance at such angles is too small, sufficient glare resistance cannot be exhibited. Therefore, R (40) is generally preferably 0.0001% or more, and R (50) is generally It is preferably 0.00001% or more. R (50) is more preferably 0.0001% or less.

4 is a reflection angle and a reflectance of the reflected light 17 of the incident light 15 incident at an angle of 30 离 from the normal line side with respect to the anti-glare layer side of the anti-glare film 11 in FIG. (The reflectance is a logarithmic scale) is an example of a chart for drawing. There are also such graphs showing the relationship between the reflection angle and the reflectance, or the reflectance at each reflection angle from which it can be read, which is called the reflection distribution. As shown in this graph, the regular reflectance R (30) is the peak value of the reflectance with respect to the incident light 15 incident at 30 ,, and has an offset from the direction of the regular reflection. Then, the reflectance tends to decrease. In the example of the reflection distribution shown in FIG. 4, the regular reflectance R (30) is about 0.2%, R (40) is about 0.0004%, and R (50) is about 0.00005%.

According to the survey conducted by the present inventors, most of the anti-glare films currently on the market are classified as a type of filler. In the anti-glare film, the relative diffused light intensity T(20) is 0.0001% or more and 0.0005% or less when injected at 20 Å, and the relative diffused light intensity T (30) is 0.00004 when 30 Å is incident. % or more of 0.00025% or less does not exist. Further, in addition to such transmission and diffusion characteristics, the regular reflectance R (30) is 0.05% or more and 2% or less, and the reflectance R (40) of the reflection angle of 40 系 is 0.0001% or more and 0.005% or less, and the reflection angle is 50. The reflectance R (50) of bismuth is 0.00001% or more and 0.0005% or less, and does not exist. As a result, there is no glare, and high contrast is exhibited, and a sufficient white anti-glare film is not exhibited while exhibiting sufficient anti-glare properties, and does not exist. On the other hand, it is understood that the anti-glare film specified by the present invention exhibits sufficient anti-glare properties and also suppresses whitening, and has excellent performance.

When the reflectance of the anti-glare film is measured, it is necessary to measure the reflectance of 0.001% or less with good precision as in the case of the relative diffused light intensity. Here, it is effective to use a detector having a wide dynamic range. As such a detector, for example, a commercially available optical power meter or the like can be used, and an aperture can be provided in front of the detector of the optical power meter, and the angle at which the anti-glare film is made can be 20 ∘. A variable angle photometer was used for the measurement. For the incident light, a visible light of 380 to 780 mm can be used as a light source for measurement, and the light emitted from a light source such as a halogen lamp can be collimated, or a laser or the like can be used. A monochromatic light source with a high degree of parallelism. In the case where the back surface is a smooth and transparent anti-glare film, since the reflection from the back surface of the anti-glare film affects the measured value, for example, it is made of a black acrylic resin sheet. In the above, it is preferable to use an adhesive or a liquid such as water or glycerin to make it optically dense, and it is preferable to measure only the reflectance of the outermost surface of the antiglare film.

[haze] Further, in order to prevent whitening and to suppress glare applied to a high-definition image display device, the anti-glare film of the present invention is generally preferable as follows: for the surface haze of the vertically incident light, The content is 0.1% or more and 5% or less, and the total haze is 5% or more and 25% or less. The full haze of the anti-glare film can be measured in accordance with the method shown in JIS K 7136. The difference between the surface haze and the internal haze is determined by measuring the internal haze by attaching a transparent film having a haze of about 0 to the uneven surface after measuring the overall haze. The surface haze can be obtained by the following formula.

Surface haze = total haze - internal haze

A transparent film having a haze of approximately 0 is attached to the uneven surface of the anti-glare film, and the haze value measured in this state is almost completely offset by the surface haze caused by the original unevenness. In fact, it can be considered as representing the internal haze. The transparent film having a haze of approximately 0 is not particularly limited as long as it has a small haze. For example, a triacetate film or the like can be used.

When the surface haze exceeds 5%, the tendency to whiten is Strong, when it is less than 0.1%, it does not exhibit sufficient anti-glare properties, so it is not ideal. Moreover, if the full haze is 5% or more, it is desirable because the glare phenomenon can be effectively removed. However, if the full haze exceeds 25%, when it is applied to an image display device, the result is that the screen becomes dark and the visibility is impaired, which is not preferable.

[reflective sharpness] Further, the anti-glare film of the present invention is generally preferably formed by using three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm in the dark portion and the bright portion at an incident angle of light of 45 ∘. The sum of the measured reflectances was _40% or less. The reflectance is measured by the method specified in JIS K 7105. In this specification, as the optical comb used in the measurement of the sharpness, the width ratio of the dark portion to the bright portion is 1:1, and the width is 0.125 mm, 0.5 mm, 1.0 mm. And 4 kinds of 2.0mm. In the case where a light comb having a width of 0.125 mm is used, in the anti-glare film defined by the present invention, since the error of the measured value is large, it is assumed that the width is not wide. The measured value in the case of a 0.125 mm optical comb is added to the sum, and the sum of the sharpness measured by using three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm is called a reflection. Sharpness. The maximum value of the reflection sharpness caused by this definition is 300%. If the reflectance is less than 40%, the image of the light source or the like is clearly reflected, and the anti-glare property is deteriorated, which is not preferable.

However, if the reflection sharpness is 40% or less, it is only reflected by fresh It is difficult to compare the advantages and disadvantages of anti-glare with lightness. This is because, when the reflection sharpness due to the above definition is 40% or less, the respective reflection sharpness measured by using three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm is used. The system is only about 10%, and the reflection of the reflection sharpness caused by measurement errors and the like cannot be ignored.

Therefore, in the present invention, the anti-glare film having a reflection sharpness of 40% or less is preferably defined by the relative diffused light intensity, and more preferably by the reflectance when it is incident with 30 Å. The combination is used as an index for appropriately evaluating the antiglare performance of the antiglare film.

[surface shape] Next, the surface shape at the uneven surface of the antiglare layer of the antiglare film will be described. The anti-glare film of the present invention is intended to more effectively suppress the glare phenomenon, and to make the texture when viewed by visual observation uniform, and to be a concave-convex surface shape factor to satisfy one or both of the following The conditions are ideal.

(1) The arithmetic mean height Pa of the cross-sectional curve constituting the uneven surface of the anti-glare layer is 0.05 μm or more and 0.2 μm or less, and the maximum cross-sectional height Pt is 0.2 μm or more and 1 μm or less, and the average length PSm is 15 μm. Above 30 μm.

(2) The uneven surface constituting the antiglare layer is provided with 50 or more convex portions of 50 or less in a region of 200 μm × 200 μm.

(3) When the apex of the convex portion constituting the uneven surface of the antiglare layer is used as a mother point, and the surface is subjected to voronoi tessellation, the average area of the polygonal shape formed is 100 μm ² or more. 1000 μm ² or less.

First, the arithmetic mean height Pa, the maximum cross-sectional height Pt, and the average length Psm at the cross-sectional curve constituting the uneven surface of the anti-glare layer will be described. These values are those specified in JIS B 0601 (=ISO 4287), and the arithmetic mean height Pa is the same as the value called the centerline average thickness.

When the arithmetic mean height Pa at the cross-sectional curve of the uneven surface is less than 0.05 μm, the surface of the anti-glare film is almost flat and does not exhibit sufficient anti-glare performance, which is not preferable. Further, when the arithmetic mean height Pa is larger than 0.2 μm, the surface shape becomes thicker and whitens are generated, and when the appearance is visually observed, the texture becomes thicker, and therefore, the system is also not ideal. When the maximum cross-sectional height Pt at the cross-sectional curve of the uneven surface is less than 0.2 μm, the surface of the anti-glare film is almost flat and does not exhibit sufficient anti-glare performance, which is not preferable.

Further, when the maximum cross-sectional height Pt is larger than 1 μm, the surface shape becomes thick, and problems such as whitening or a decrease in texture are caused, and therefore, it is not preferable. When the average length PSm at the cross-sectional curve of the uneven surface is less than 15 μm, it is not preferable because sufficient anti-glare property cannot be obtained. This is because if the average length PSm is too small, the peak value of the unevenness (the surface inclination angle at this point can be considered to be almost 0 ∘) is close to the system. Therefore, when visually observed, the image will be imaged. Therefore. Also, when the average length PSm is larger than 20 μm, when The texture at the time of visual observation is thickened, and therefore, the system is not ideal.

The arithmetic mean height Pa, the maximum profile height Pt, and the average length PSm at the profile curve of the uneven surface are determined according to JIS B 0601, and can be measured using a commercially available contact surface roughness meter. Further, the surface shape can be measured by a device such as a conjugate focal length microscope, an interference microscope, or an atomic force microscope (AFM), and can be obtained by calculation from the three-dimensional information of the surface shape. It. In addition, when calculating from the three-dimensional information, in order to secure a sufficient reference length, it is preferable to measure three or more points in a region of 200 μm × 200 μm or more, and it is preferable to use the average value as a measured value.

Next, the number of convex portions observed on the uneven surface will be described. If the number of convex portions at the uneven surface is small, when it is combined with a high-definition image display device, it may cause glare due to interference with the pixels, making the image difficult to recognize. And the texture is worse, so it is not ideal. Further, if the number of the convex portions is excessive, as a result, the inclination angle of the surface uneven shape becomes steep, and whitening is likely to occur. Here, it is preferable that the uneven surface is provided with 50 or more convex portions of 50 or less in a region of 200 μm × 200 μm.

When the number of convex portions at the uneven surface of the anti-glare film is taken out, the surface shape can be measured by a device such as a conjugate focus microscope, an interference microscope, or an atomic force microscope, and each surface of the anti-glare film can be taken out. The 3-dimensional coordinate value of the point is determined by the mechanism shown below, and the number is counted. That is, when paying attention to any point on the surface of the anti-glare film When there is no point above the point, the elevation is higher than the point of interest, and the elevation of the point at the concave and convex surface is the elevation and the lowest point of the highest point of the concave and convex surface. When the middle of the elevation is higher, the point is set as the apex of the convex portion, and the number of vertices of the convex portion thus extracted is counted as the number of convex portions.

More specifically, as shown in FIG. 5, in general, at an arbitrary point 21 on the surface of the anti-glare film, a radius of 2 μm to 5 μm parallel to the anti-glare film reference surface 23 is drawn around the point 21 In the case of a circle, when there is a point on the surface 22 of the anti-glare film contained in the projection surface 24 of the circle, there is no point having a higher elevation than the point 21 of interest, and the point is at the uneven surface When the elevation is higher than the middle of the elevation of the highest point of the concave-convex 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 convex portions is extracted. In this case, the radius of the circle 24 is preferably about 3 μm in order to prevent the unevenness of the surface of the sample from being counted, and to make it a size that does not include a plurality of convex portions. In the measurement, in order to reduce the error, it is preferable to measure the area of 200 μm × 200 μm by three or more points, and it is preferable to use the average value as the measured value.

When a conjugated focus microscope is used, it is preferable to measure the magnification of the objective lens by about 50 times and reduce the resolution. This is because if the measurement is performed at a high resolution, the fine unevenness of the surface of the sample is also measured, and the counting of the convex portion is hindered. There is also a reason that if the objective lens is set to a low magnification, the resolution in the height direction is also lowered, and in the case of a sample having a small amount of unevenness, the measurement of the surface shape becomes difficult. In this case After the measurement is performed by a high-magnification objective lens, the obtained data is low-pass filtered to discard the component having a high spatial frequency, thereby observing the surface on the uneven surface. The small difference becomes difficult to recognize, and then the number of the convex portions can be counted.

Next, the average area of the formed polygon will be described with respect to when the convex apex of the uneven surface is used as a mother point and the surface is subjected to voronoi tessellation. First, if the description is directed to the Morono division, when a plurality of points (referred to as a mother point) are arranged on the plane, it is determined that the arbitrary point in the plane is closest to the parent point. When the plane is divided, the obtained map is called a Molono diagram, and the division is called a Molino division. In FIG. 6, an example in which the apex of the convex portion at the surface of the anti-glare film is used as a mother point and the surface is divided into molino is shown, and the points 26 and 26 of the four corners are mother points, and include The polygons 27 and 27 of each of the mother points are formed by the partition of Molono and are called the Molonoyi region or the Morono Polygon, but Hereinafter, it is called a Molino Polygon. In the figure, the portions 28 and 28 which are covered with a light color are described later. In the Molono diagram, the number of mother points is consistent with the number of Molonoyi regions.

In this manner, the average area of the Molino polygon formed by the Molinoyi division with the apex of the convex portion as the mother point is preferably 100 μm ² or more and 1000 μm ² or less. When the average area at this time is less than 100 μm ² , the inclination angle of the surface of the anti-glare film becomes steep, and as a result, the whitening system is likely to be generated, which is not preferable. Further, when the average area of the Morono polygon is larger than 1000 μm ² , the surface shape of the unevenness becomes thick, and glare is likely to occur, and the texture is also deteriorated, which is not preferable.

The conjugate focus microscope and the interference microscope can be obtained by extracting the average area of the Molino poly polygon obtained by dividing the vertices of the convex portion on the surface of the anti-glare film as the mother point. An atomic force microscope (AFM) device is used to measure the surface shape, and the 3-dimensional coordinate value of each point on the surface of the anti-glare film is taken out, and the Molinoyi segmentation is performed by the mechanism shown below. Remove the average area of the Molono Poly polygon. That is, according to the mechanism previously described with reference to Fig. 5, first, the apex of the convex portion on the surface of the anti-glare film is taken out, and then the apex of the convex portion is projected onto the reference surface of the anti-glare film. Then, all the 3-dimensional coordinates obtained by the measurement of the surface shape are all projected on the reference surface, and Moolo is performed by causing all the points to be projected to belong to the closest parent point. The Nuo division is divided, and the average area of the Molino poly polygon is taken out by taking out the area of the polygon obtained by the division. In order to reduce the error during the measurement, the number of the previous convex portions is counted for the Molino Polygon adjacent to the boundary of the measurement field of view. However, when the average area is obtained, it is not counted. . Moreover, in order to reduce the measurement error, it is preferable to measure three or more points in a region of 200 μm × 200 μm or more, and it is preferable to use the average value as a measured value.

As a part of the description of the prior art, FIG. 6 is a view showing a Molono diagram in which the vertices of the convex portions of the anti-glare film are used as the mother points to perform the morpholysis. Most existing mother points 26, 26 are anti-glare The apex of the convex portion of the film is divided by Molono, and one Mooron Polygon 27 is assigned to one of the mother points 26. In the figure, the Molino Polygons 28 and 28 which are adjacent to the boundary of the field of view and are colored in a pale color are generally not counted in the calculation of the average area as described above. In addition, in this figure, for a part of the mother point and the Molino Polygon, the pull-out line and the symbol are attached, but there is a majority of the mother point and the Molino Polygonal system, especially The above description and this figure should be easily understood.

[Transparent support and anti-glare layer] The anti-glare film of the present invention is formed by an anti-glare layer having a fine uneven surface on a transparent support. The transparent support is formed by supporting an antiglare layer having a concave-convex surface as a support, and is substantially transparent and transparent. Examples of the transparent support include cellulose triacetate, polyethylene terephthalate, polymethyl methacrylate, polycarbonate, and a Norbornene compound as a monomer. A solvent cast film or an extruded film formed of a thermoplastic resin such as an amorphous cyclic polyolefin.

The anti-glare layer is formed on the transparent support as a layer to which surface irregularities satisfying the general transmission and diffusion characteristics as described above are provided. Such an anti-glare film may be coated on a transparent support by a resin solution in which a filler is dispersed, which is used in the prior art, and the filler is coated from the coating film by adjusting the thickness of the coating film. The surface is exposed to be formed by forming a random unevenness on the transparent support, but it is preferable. The surface unevenness of the antiglare layer is formed by transfer from a mold having a concave-convex surface. In addition, it is preferable that 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, and the difference in refractive index between the binder and the binder resin is 0.01 or more and 0.06 or less. The fine particles are 10 to 100 parts by weight, and further, the fine particles are completely buried in the anti-glare layer, and the fine particles do not affect the uneven shape of the surface. In this manner, by independently controlling the surface unevenness of the surface and the internal diffusion of the anti-glare film, it is possible to separate the surface unevenness shape of the anti-glare film which mainly determines the reflection characteristics from the composition of the anti-glare layer which mainly determines the transmission characteristics. Control. As a result, the above optical characteristics can be easily achieved. The formation of such an anti-glare layer will be described in detail later.

The anti-glare film of the present invention can exhibit a sufficient anti-glare function even when it does not have a low-reflection film on the outermost surface (that is, on the uneven surface side), but it can also be at the outermost surface. It is used in a state in which a low-reflection film is attached. The low-reflection film can be formed by providing a layer of a lower refractive index material having a lower refractive index on the anti-glare layer. Specific examples of such a low refractive index material include lithium fluoride (LiF), magnesium fluoride (MgF ₂ ), and fluorination in a propylene resin or an epoxy resin. An inorganic low-reflection material made of fine particles of inorganic materials such as aluminum (AlF ₃ ), cryolite (3NaF.AlF ₃ or Na ₃ AlF ₆ ); and fluorine-based or lanthanide organic compounds, thermoplastic resins An organic low-reflection material such as a thermosetting resin or an ultraviolet curable resin.

[Manufacturing method of mold for producing anti-glare film] Next, a method suitable for producing the antiglare film of the present invention and a method for producing the antiglare film on which the surface is formed with irregularities will be described. In the anti-glare film of the present invention, the uneven surface of the mold can be transferred onto the transparent resin film by using a mold having irregularities formed with a specific shape, and the transparent resin film to which the uneven surface is transferred can be removed from The method of stripping the mold to facilitate the manufacture. More specifically, it is produced by applying copper plating or nickel plating to the surface of the metal, and grinding the plating surface, and then causing the fine particles to impinge on the polishing surface to form the unevenness. And applying a process for passivating the uneven shape, and then applying chromium plating to the uneven surface to form a mold, and transferring the uneven surface of the mold to the resin coated on the transparent support, and then, The resin to which the irregularities are transferred is peeled off from the mold together with the transparent support. In this method, in order to obtain a mold having irregularities, copper plating or nickel plating is applied to the surface of the metal, and the plating surface is ground, and then the fine particles are caused to impinge on the polishing surface to form irregularities. A process for passivating the uneven shape is applied, and then chrome plating is applied to the uneven surface to form a mold.

First, at the surface of the metal substrate on which the fine particles are struck to form irregularities and further the chromium plating layer is formed, copper plating or nickel plating is applied. In this manner, by applying copper plating or nickel plating to the surface of the metal constituting the mold, the adhesion or gloss of the chromium plating in the subsequent work can be improved. When chrome plating is applied to the surface of iron or the like, or when embossing or beading is performed at the surface of chrome plating to form irregularities and chrome plating is applied again, it is as in the prior art. In general, the surface thereof is liable to become rough and to cause fine chipping, which may cause an undesired influence on the shape of the anti-glare film. On the other hand, it has been found that such a problem can be eliminated by applying copper plating or nickel plating at the surface. This is because copper plating or nickel plating has a high coating property and a high smoothing effect. Therefore, a small unevenness or pit of a metal substrate is buried to form a flat and lustrous one. The reason for the surface. Through the characteristics of such copper plating and nickel plating, it is presumed that the roughness of the surface caused by the minute irregularities or pits existing in the metal substrate is eliminated, and, due to the plating of copper plating or nickel plating. The sexual system is high, so it is conceivable that the generation of small fragments is reduced.

Here, the so-called copper or nickel may be a pure metal of its own, and may be an alloy mainly composed of copper or an alloy mainly composed of nickel. Therefore, the meaning of copper in this specification includes copper and a copper alloy, and the meaning of nickel includes nickel and a nickel alloy. Copper plating and nickel plating can be carried out by electrolytic plating or electroless plating, respectively, but electrolytic plating is usually employed.

As a metal suitable for constituting a mold, aluminum or iron or the like is exemplified from the viewpoint of cost. Further, from the viewpoint of handling convenience, it is more preferable to use lightweight aluminum. The so-called aluminum or iron may be a pure metal or an alloy mainly composed of aluminum or iron. Applying copper plating or nickel plating to the surface of the metal substrate, and then grinding the plated surface to obtain a smoother and glossy surface, and then causing the particles to impinge on the surface to form a fine Bump and apply The uneven shape is processed by passivation, and then chromium plating is applied thereto to form a mold.

When copper plating or nickel plating is applied, if the plating layer is too thin, the influence of the base metal cannot be completely eliminated. Therefore, the thickness is preferably 10 μm or more. Although there is no threshold for the upper limit of the thickness of the plating layer, since the system is also related to the cost, it is generally sufficient if it is about 500 μm.

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

Fig. 7 is a cross-sectional view showing an engineering mode display until a mold is obtained, taking a case where a flat plate is used as an example. FIG. 7(A) shows a section of a substrate to which copper plating or nickel plating is applied, and after mirror polishing, is applied, and at the surface of the metal substrate 31, a plating layer 32 is formed. This surface is the polishing surface 33. Concavities and convexities are formed by impinging fine particles at the surface of the electroplated layer 32 after such mirror polishing. Fig. 7(B) is a schematic cross-sectional view of the substrate 31 after the fine particles are struck, and a microscopic concave surface 34 having a partial spherical shape is formed by impacting the fine particles.

(C) of FIG. 7 is a cross-sectional schematic view of the substrate 31 after the irregularities are passivated on the surface on which the irregularities are formed by the fine particles, and (C1) is shown by etching. In the state after being passivated, (C2) is a state in which it is passivated by copper plating. In addition, in (C1), it is equivalent to before passivation by etching. The state of the partial spherical concave surface in the state of (B) is shown by a broken line in the example of the etching treatment of (C1), and the concave surface 34 and the acute-angled projection shown in (B) are etched. It is flattened and formed with a shape 36a which is formed by passivating the acute-angled projections on the partial spherical surface. On the other hand, in the case of (C2) using copper plating, on the concave surface 34 shown in (B), a copper plating layer 35 is formed, whereby a partial spherical surface is formed. The sharp-angled protrusions passivate the shape 36b.

Then, by applying chromium plating, the uneven shape of the surface is further passivated. Fig. 7(D) is a cross-sectional schematic view showing the application of chromium plating, and (D1) is a method of applying chromium plating to the uneven surface 36a which is passivated by etching as shown in (C1). And (D2) is a chrome plating which is applied to the copper plating layer 35 shown in (C2).

In the example in which the etching treatment from (C1) to (D1) is employed, a chromium plating layer 37 is formed on the surface 36a in a state of being passivated by etching as shown in (C1). 38 is a state in which it is more passivated by chrome plating than the uneven surface 36a of (C1), in other words, a state in which the uneven shape is relaxed. Further, in the example of copper plating from (C2) to (D2), a copper plating layer is formed on the fine concave surface of the substrate 31 formed on the copper or the nickel plating layer 32. 35, and further, a chromium plating layer 37 is formed thereon, and the surface 38 is in a state of being more passivated than the uneven surface 36b of (C2), in other words, a state in which the uneven shape is relaxed. In this manner, after the fine particles are struck against the copper or the surface of the nickel plating layer 32 to form irregularities, a process of passivating the uneven shape is applied, and on the surface 36 (36a or In the case of 36b), chrome plating is applied, whereby a mold having substantially no flat portion can be obtained. Moreover, such a mold is suitable for obtaining an anti-glare film exhibiting desired optical characteristics.

In the plating layer made of copper or nickel on the substrate, the fine particles are struck in a state where the surface is polished, but it is particularly preferable to polish it to a state close to the mirror surface. This is because the metal plate or the metal roll that becomes the base material is subjected to machining such as cutting or grinding in order to achieve the desired accuracy, and processing is left on the surface of the substrate due to the processing. The reason for the traces.

Even in the state where copper plating or nickel plating is applied, there are cases where the processing marks remain, and the surface does not necessarily become completely smooth after the plating. In the state in which the deep processing marks remain, even if the surface of the substrate is deformed by the impact of the fine particles, the unevenness of the processing marks and the like may be deeper than the irregularities formed by the fine particles, and the processing may be performed. Traces, etc. affect the possibility of residue.

When an anti-glare film is produced by using such a mold, there is a case where the optical characteristics are unpredictably affected.

The method of polishing the surface of the substrate to which the electric wave is applied is not particularly limited, and any of a mechanical polishing method, an electrolytic polishing method, and a chemical polishing method can be used. Examples of the mechanical polishing method include a super finish method, a fluid polishing method, and a buffing wheel polishing method. The surface roughness after the polishing is expressed by the average thickness of the center line, and is preferably 0.5 μm or less, and more preferably 0.1 μm or less. If Ra becomes too large, even if it hits the particles, the surface of the metal is deformed. There is a possibility that the influence of the surface roughness before deformation remains, which is not preferable. Further, the lower limit of Ra is not particularly limited, and since there is a limit in terms of processing time and workability, there is no need for special designation.

As a method of impinging fine particles on a substrate to which an electroplated surface is applied, a jet processing method is suitably used. In the jet processing method, there are a sandblasting method, a beading method, a liquid blasting method, and the like. As the particles used in such processing, it is preferable to have a shape close to a spherical shape as compared with a shape having an acute angle, and a hard material which does not cause breakage and sharp angle during processing. The particles are ideal. As the particles satisfying such conditions, spherical zirconium beads or alumina beads are suitably used in the ceramic-based particles. Further, among the metal-based particles, it is preferable to use steel or stainless steel beads. Further, particles in which ceramic or metal particles are held in a resin binder can also be used.

As the particles which collide with the surface to which the plating is applied to the substrate, it is preferable to use an average particle diameter of 10 to 150 μm, and it is more preferable to use spherical fine particles, whereby it is possible to produce an excellent display. Anti-glare film with anti-glare properties. When the average particle diameter of the fine particles is smaller than 10 μm, it is difficult to form sufficient unevenness on the surface to which the plating is applied, and it is difficult to obtain a sufficient antiglare function. On the other hand, when the average particle diameter of the fine particles is larger than 150 μm, the surface unevenness becomes thick, and glare is likely to occur and the texture is lowered. Here, when processing is performed using fine particles having an average particle diameter of 15 μm or less, it is suitably dispersed in a dispersion so that particles do not aggregate due to static electricity or the like. Wet blasting in the media and processing is ideal.

In addition, the pressure at the time of impacting the fine particles and the distance between the use of the fine particles from the nozzle for spraying the fine particles to the surface also affect the surface shape after the processing and the surface shape of the anti-glare film. It is suitable for selection in the following range depending on the type or particle size of the fine particles to be used, the type of the metal, the shape of the nozzle for spraying the fine particles, and the desired uneven shape: 0.05 to 0.4 MPa. The gage pressure is about 200 to 600 mm from the nozzle for spraying the particles to the surface of the metal for the amount of fine particles per 1 cm ² : 4 to 12 g of the surface area of the metal to be treated.

The uneven shape formed by impinging fine particles on the surface of the substrate to which the plating is applied is generally as follows: the arithmetic mean height Pa at the cross-sectional curve is 0.1 μm or more and 1 μm or less, and the profile is The ratio Pa/PSm of the arithmetic mean height Pa to the average length PSm at the curve is 0.02 or more and 0.1 or less. When the arithmetic mean height Pa is smaller than 0.1 μm or smaller than Pa/PSm is less than 0.02, when a project for passivating the uneven shape is applied before the chromium plating process, the uneven surface is almost flat. A mold that is difficult to obtain the desired surface shape. Further, when the arithmetic mean height Pa is larger than 1 μm or larger than Pa/PSm is larger than 0.1, when a work for passivating the uneven shape is applied before the chromium plating process, it is necessary to strongly The conditions are carried out, and it is easy to make the control of the surface shape difficult.

In the case of such a copper plating or a substrate having irregularities formed on the surface of the nickel plating, a process of passivating the uneven shape is applied. As the concave and convex shape The passivation process is generally performed by etching or copper plating as previously described with reference to (c) and (d) of FIG. By performing the etching treatment, the sharp portion of the uneven shape produced by the impact of the fine particles disappears. Therefore, when it is used as a mold, the optical characteristics of the produced anti-glare film change in a desired direction. also. Since copper plating is strong because of its smoothing action, the effect of passivating the uneven shape is stronger than that of chromium plating. Therefore, when it is used as a mold, the optical characteristics of the produced anti-glare film change in a desired direction.

Etching process, typically based ferric chloride (FeCl ₃₎ solution, cupric chloride (CuCl ₂₎ solution, an alkaline etchant _{(Cu (NH 3) 4 Cl} 2) , etc., and etching is performed via the surface, However, a strong acid such as hydrochloric acid or sulfuric acid may be used, and reverse electrolytic etching by applying a potential different from that at the time of electrolytic plating may also be used. The degree of passivation of the concavities and convexities after the etching treatment is different depending on the type of the base metal, the size of the concavities and the like obtained by sand blasting, and the like, and therefore cannot be generalized, but the degree of passivation can be controlled. The largest factor in the factor is the amount of etching. Here, the amount of etching refers to the thickness of the plating layer which is removed by etching. When the etching amount is small, the effect of passivating the uneven surface obtained by the method such as sand blasting is insufficient, and the optical characteristics of the antiglare film obtained by transferring the uneven shape to the transparent film are not preferable. On the other hand, if the etching amount is too large, the uneven shape is almost eliminated, and the mold is almost flat, so that the anti-glare property cannot be exhibited. Here, the etching amount is preferably 1 μm or more and 20 μm or less, and more preferably 2 μm or more and 10 μm or less.

When copper plating is used as the passivation process, the degree of passivation of the unevenness differs depending on the type of the base metal, the size and depth of the unevenness obtained by sandblasting, and the type of plating, and therefore, In general, however, the largest factor in the factors that can control the degree of passivation is the plating thickness. If the thickness of the plating layer is thin, the effect of passivating the uneven surface obtained by sandblasting or the like is insufficient, and the optical characteristics of the antiglare film obtained by transferring the uneven shape to the transparent film are not good. On the other hand, if the plating thickness is too thick, the uneven shape is almost eliminated in addition to the poor productivity, and therefore, the anti-glare property cannot be exhibited. Here, the thickness of the copper plating is preferably 1 μm or more and 20 μm or less, and more preferably 4 μm or more and 10 μm or less.

In this way, by passivating the surface shape of the substrate on which the unevenness is formed at the surface of the copper plating or the nickel plating, chromium plating is further applied to further passivate the surface of the unevenness, and at the same time, the surface hardness is formed. High metal plate. The degree of passivation of the unevenness at this time differs depending on the type of the base metal, the size and depth of the unevenness obtained by sandblasting, and the type or thickness of the plating. Therefore, it cannot be generalized. The largest factor in the factor controlling the degree of passivation is still the plating thickness.

If the thickness of the chromium plating layer is thin, the effect of passivating the uneven surface obtained before the chromium plating process is insufficient, and the optical characteristics of the antiglare film obtained by transferring the uneven shape to the transparent film are not good. On the other hand, if the plating thickness is too thick, it will be in addition to poor productivity. A protrusion-like plating defect called a nodule is generated. The thickness of the chromium plating is preferably 1 μm or more and 10 μm or less, and more preferably 2 μm or more and 6 μm or less.

Chromium plating, which has a luster, a high hardness, and a small coefficient of friction, can impart good release properties. Although the type of chrome plating is not particularly limited, it is preferably chrome plating which is so-called gloss chrome plating or decorative chrome plating, which can exhibit good gloss. Chromium plating is usually carried out by electrolysis, and as its electroplating bath, an aqueous solution containing anhydrous chromic acid (CrO ₃ ) and a small amount of sulfuric acid is used. The thickness of the chromium plating can be controlled by adjusting the current density and the electrolysis time.

The surface of the mold to which chrome plating is applied is preferably 800 or more in Vickers hardness, and more preferably 1000 or more. If the Vickers hardness is low, in addition to the durability of the mold, the hardness is lowered in the chromium plating, which is highly likely to occur in the plating bath composition or in the electrolytic condition during the plating treatment. There are abnormalities, and there are also high possibilities for the occurrence of defects to give adverse effects.

In the case of the surface of the metal substrate which becomes the mold, it is disclosed in the patent document 1 (JP-A-2002-189106) or the patent document 4 (JP-A-2004-90187). Applying chrome plating, however, depending on the type of substrate and chrome plating before plating, there are many cases where the surface becomes rough after plating or a small number of cracks due to chrome plating are generated. As a result, the optical characteristics of the produced anti-glare film change in an undesired direction. If the plating surface is rough, it is not suitable for anti-glare. A mold for a film. This is because, in general, in order to eliminate the roughness, the surface is polished after chrome plating. However, as will be described later, in the present invention, the polishing of the surface after plating is not preferable. Therefore. In the present invention, such a problem which is apt to occur in chromium plating is eliminated by applying copper plating or nickel plating at the base metal.

When the processing for passivating the uneven shape is not applied before the application of the chromium plating, in order to sufficiently passivate the sharp portion of the uneven shape formed by the impact of the fine particles, it is necessary to make the chromium plating thick. However, if the thickness of the chromium plating is too thick, nodules are likely to occur, which is not preferable. Further, when the thickness of the chromium plating is thin, the uneven shape formed by the impact of the fine particles cannot be sufficiently passivated, and the mold having the desired surface shape cannot be obtained. Therefore, the anti-glare produced by using the mold is used. The film also does not exhibit excellent anti-glare properties.

In the above-mentioned Patent Document 1 (JP-A-2002-189106), it is described that a concave-convex surface is formed by a sandblasting method or a bead method at a roller which is subjected to chromium plating on the surface of iron. Then, in the case of applying the chrome plating, in the case of the surface of the drum, the application of the spray is described in the patent document 3 (Japanese Laid-Open Patent Publication No. 2004-29240) and the patent document 4 (JP-A-2004-90187). Bead method or sandblasting. However, this is not a method for actively applying a passivation process after impacting fine particles to form a concave-convex shape, and further applying a chromium plating process to passivate the surface uneven shape, if it is based on the review by the present inventors. If the processing for passivating the surface shape is not actively applied as described above, it is impossible to manufacture an anti-glare film exhibiting excellent anti-glare properties.

Further, it is not preferable to apply plating other than chromium plating to the surface of the metal to which the unevenness is added. This is because the hardness and wear resistance of the plating other than chromium are low, and the durability as a mold is lowered, and in use, the unevenness is degraded by friction and the mold is damaged. In the antiglare film obtained from such a mold, the possibility that a sufficient antiglare function cannot be obtained is high, and the possibility of occurrence of defects on the film also becomes high.

After chrome plating, it is advantageous to use the chrome plating surface as the uneven surface of the mold without polishing the surface. In the above-mentioned Patent Document 4 (JP-A-2004-90187), it is described that the surface after plating is polished. However, in the case of polishing the chromium plating surface, it is not in the present invention. ideal. The reason for this is that, by polishing, since a flat portion is generated at the outermost surface, there is a possibility that the optical characteristics are deteriorated, and the control factor for the shape is also increased. Therefore, the reproducibility is Excellent shape control systems become difficult and the like. Fig. 8 is a view showing the process of passivating the concavo-convex shape obtained by striking the microparticles. Here, after the etching treatment shown in (C1) of Fig. 7, the same application (D1) is applied. In the case where the surface after chrome plating is polished, a cross-sectional schematic view of a metal plate having a flat surface is produced. By grinding, in the surface irregularities 38 of the chromium plating layer 37 formed at the surface of the copper or nickel plating layer 32, a part of the convex portions are cut off to produce a flat surface 39.

In FIG. 8, although an example of the case where the chrome-plated surface after etching is etched as shown in (D1) of FIG. 7 is shown, The same applies to the case where chrome plating is applied after copper plating as shown in (D2) of Fig. 7, and if the surface is polished, a flat surface is formed in the same manner.

[Method for producing anti-glare film] Next, an engineering description of the manufacture of the anti-glare film using the mold thus obtained is described. The anti-glare film was obtained by transferring the shape of the mold obtained by the method described above to the transparent resin film. The transfer of the film shape to the film is preferably carried out by embossing. Examples of the embossing include a UV embossing method using a photocurable resin and a hot embossing method using a thermoplastic resin.

In the UV embossing method, a photocurable resin layer is formed on the surface of the transparent support, and the photocurable resin layer is pressed against the uneven surface of the mold and hardened, whereby the mold is pressed The uneven surface is transferred to the photocurable resin layer. Specifically, the ultraviolet curable resin is applied to the transparent support, and the applied ultraviolet curable resin is adhered to the uneven surface of the mold, and ultraviolet rays are irradiated from the transparent support side to cause ultraviolet rays. After the hardening type resin is cured, the support formed of the cured ultraviolet curable resin layer is peeled off from the mold, whereby the shape of the mold is transferred to the ultraviolet curable resin. The type of the ultraviolet curable resin is not particularly limited. Further, although it is expressed by an ultraviolet curable resin, it may be a resin which can be cured by visible light having a longer wavelength than ultraviolet light by suitably selecting a photoinitiator. That is, the so-called ultraviolet curing resin here is It is a general term for those who also include such a visible light curing type resin. On the other hand, in the hot embossing method, a transparent thermoplastic resin film is pressed against a 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, UV embossing is preferred.

The transparent support used in the production of the anti-glare film may be a resin film which is substantially optically transparent, and for example, cellulose triacetate or polyethylene terephthalate may be used. A solvent cast film formed of a thermoplastic resin such as polymethyl methacrylate, polycarbonate, or a norbornene-based compound as a monomeric amorphous cyclic polyolefin, or extruded Film and the like.

As the ultraviolet curable resin, it can be used in the market. For example, a polyfunctional acrylate such as trimethylolpropane triacrylate or pentaerythritol tetraacrylate may be used singly or in combination of two or more kinds thereof, and it may be combined with "IRGACURE". 907", "IRGACURE 184" (above, Ciba specialty chemicals), Lucirin A photo-recovering initiator such as TPO (manufactured by BASF Corporation) is mixed and used as an ultraviolet curable resin.

As the thermoplastic resin film to be used in the hot embossing method, any material can be used as long as it is substantially transparent. For example, polymethyl methacrylate or polycarbonate can be used. A solvent cast film of polyethylene terephthalate, cellulose triacetate, or a thermoplastic resin such as a non-crystalline cyclic polyolefin having a Norbornene compound as a monomer. Or push out the film and so on. Such a thoroughness The clear resin film may be a transparent support when the UV embossing method described above is employed.

The anti-glare film of the present invention uses a mold having irregularities formed in a specific shape, and transfers the uneven surface of the mold to a resin coated on the transparent support, and then, is transferred It is preferable that the resin of the uneven surface is peeled off from the mold to form a fine uneven shape on the surface, and the resin used for the transfer contains an average particle diameter of 5 μm or more and 15 μm or less with respect to 100 parts by weight of the adhesive resin. It is preferable that the difference in refractive index between the adhesive resin and the adhesive resin is 0.01 to 100 parts by weight, and 10 to 100 parts by weight of the fine particles are preferable.

When the average particle diameter of the fine particles in the binder resin is less than 5 μm, the value on the wide-angle side of the diffusion diffusion distribution increases, and as a result, when applied to an image display device, the contrast is lowered, so not ideal. On the other hand, when the average particle diameter exceeds 15 μm, it is desirable from the viewpoint of completely burying the particles in the binder resin as will be described later, in order to bury the particles, the film thickness is increased. tendency. As a result, there is a problem that curling or aggregation occurs easily during the resin coating process.

Further, when the difference in refractive index between the fine particles and the binder resin is less than 0.01, the internal diffusion effect due to the fine particles is small, and therefore, in order to impart specific diffusion characteristics and haze to the antiglare layer, the glare is eliminated. It is necessary to add a large amount of fine particles to the binder resin, which is not desirable from the viewpoint of completely burying the microparticles in the binder resin. On the other hand, if the refractive index difference exceeds 0.06, the refractive index difference is large. Therefore, the reflectance at the interface between the binder resin and the fine particles is increased, and as a result, the rear diffusion system is increased, and the total light transmittance is lowered, which is not preferable. As a general ultraviolet curable resin as described above, since the cured product exhibits a refractive index of about 1.50, the fine particles can be appropriately blended from the refractive index of 1.40 to 1.60 to the design of the antiglare film. Make a choice. As the fine particles, resin beads are preferably used, and those which are almost spherical are preferable. In the following, examples of suitable resin beads are disclosed.

Tripolyamine beads (refractive index 1.57) polymethyl methacrylate beads (refractive index 1.49) polymethacrylic acid / 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), Resin beads (refractive index 1.46), etc.

Further, such fine particles are preferably not affected by the uneven shape of the surface, that is, it is preferable to completely bury the particles in the binder resin. This is because when the fine particles protrude from the surface, the shape of the surface irregularities changes depending on the shape of the fine particles, and the reflection characteristics (anti-glare property or whitening, etc.) of the anti-glare film are affected. When such microparticles protrude from the surface, in addition to the surface shape of the above-mentioned mold, the shape, concentration, dispersibility, and the like of the particles must be taken into consideration, and the surface shape is designed, and therefore, the surface shape is design. Control system becomes It is complicated and it becomes difficult to get the expected characteristics. Therefore, it is desirable to control the surface shape mainly affecting the reflection characteristics by only the mold, and to control the diffusion characteristics independently by the combination of the resin and the particles.

[Anti-glare polarizer] The anti-glare film of the present invention, which is generally constituted as described above, is excellent in anti-glare effect, can effectively prevent whitening, and can effectively suppress occurrence of glare and reduction in contrast, and therefore, is attached to an image display device. At the time, its visibility is excellent. When the image display device is a liquid crystal display, the anti-glare film can be applied to a polarizing plate. In other words, the polarizing plate is generally formed by laminating a protective film on at least one surface of a polarizing element formed by a polyvinyl alcohol-based resin film which is absorbing iodine or a dichroic dye. However, if one of the protective films is formed of the antiglare film of the present invention, and the polarizing element and the antiglare film of the present invention are bonded to the transparent support side of the antiglare film, it can be formed. Anti-glare polarizing plate. At this time, the other side of the polarizing element can be maintained as it is, or another protective film or an optical film can be laminated, or an adhesive layer for bonding it to the liquid crystal cell can be formed. Further, a polarizing plate to which a protective film is bonded to at least one surface of the polarizing element may be bonded to the transparent support side of the anti-glare film of the present invention to form an anti-glare polarizing plate. Further, in the polarizing plate to which the protective film is bonded, an anti-glare polarizing plate can be formed by imparting irregularities such as the above-described general anti-glare property to the surface of the protective film on one side.

[Portrait display device] The image display device of the present invention is a combination of an anti-glare film having a specific surface shape as described above or an anti-glare polarizing plate and an image display element. In this case, the image display device is represented by a liquid crystal panel including a liquid crystal cell in which a liquid crystal is sealed between the upper and lower substrates, and the alignment state of the liquid crystal is changed by application of a voltage, and the image is displayed. In addition, the anti-glare film of the present invention can also be applied to various types of displays known as plasma display panels, CRT displays, and organic EL displays. On the other hand, the above-described anti-glare film is placed on the side of the image display device to form an image display device. In this case, the uneven surface of the antiglare film, that is, the side where the antiglare layer side is made to the outside (the viewing side) is disposed. The anti-glare film can be directly bonded to the surface of the image display element, and when the liquid crystal panel is used as an image display means, for example, it can be bonded to the surface of the liquid crystal panel via a polarizing element as described above. . In the image display device including the anti-glare film of the present invention, the incident light can be diffused by the unevenness on the surface of the anti-glare film, and the reflected image can be lightened. Excellent visibility.

Moreover, even when the anti-glare film of the present invention is applied to a high-definition image display device, the glare phenomenon which is seen in the previous anti-glare film does not occur, and it is sufficient Into the performance of prevention of efficacy, prevention of whitening conditions, inhibition of glare, suppression of reduction of contrast, etc.

Example

The invention is further illustrated by the following examples, but the invention is not limited by the examples. In the example, the "%" and the "part" indicating the content and the amount of use are based on the weight unless otherwise specified. Further, in the following examples, the evaluation method for the mold or the anti-glare film is as follows.

1. Determination of the Vickers hardness of the mold: The ultrasonic hardness tester "MIC10" manufactured by Krautkramer Co., Ltd. was used, and the Vickers hardness was measured by the method of JIS Z 2244. The measurement is carried out at the surface of the mold itself.

2. Determination of optical properties of anti-glare film: (diffusion distribution) The anti-glare film is bonded to the glass substrate so that the uneven surface thereof becomes a surface, and is irradiated from He-Ne on a glass surface side thereof in a direction inclined by a specific angle with respect to the film normal. The parallel light from the laser is measured on the uneven surface side of the anti-glare film to measure the transmitted diffused light intensity in the normal direction of the film. In the measurement of the reflectance, "329203 optical power sensor" and "3292 optical power meter" manufactured by Yokogawa Electric Co., Ltd. were used.

(reflection distribution) On the uneven surface of the anti-glare film, it is inclined 30 from the normal to the film. . The direction is to illuminate the parallel light from the He-Ne laser, and the measurement of the change in the angle of the reflectance in the plane including the film normal and the irradiation direction is performed. In the measurement of the reflectance, "329203 optical power sensor" and "3292 optical power meter" manufactured by Yokogawa Electric Co., Ltd. were used.

(haze) The haze of the anti-glare film was measured using a haze meter "HM-150" manufactured by Murakami Color Research Institute, JIS K 7136. In order to prevent the bending of the sample, an optically transparent adhesive is used, and the uneven surface is bonded to the glass substrate so that the uneven surface is a surface, and the full haze is measured in this state. When the internal haze was measured, it was carried out by attaching a cellulose acetate film having a haze of almost 0 to the uneven surface of the anti-glare film by glycerin.

(reflective sharpness) The reflection sharpness of the anti-glare film was measured using an image clarity measuring device "HM-150" type manufactured by SUGA Testing Machine Co., Ltd. of JIS K 7105. In this case, in order to prevent the bending of the sample, an optically transparent adhesive is used, and the uneven surface is bonded to the glass substrate so as to have a surface, and then measured. also. In order to prevent reflection from the glass surface of the back surface, a black acrylic resin sheet having a thickness of 2 mm is adhered to the glass plate surface of the glass plate to which the anti-glare film is bonded, and in this state, Light from the sample (anti-glare The film was injected sideways and measured. The measured value here is a total value of values measured using three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm, respectively, in the dark portion and the bright portion.

3. Determination of the surface shape of the anti-glare film: The surface shape of the anti-glare film was measured using a conjugate focus microscope "PLμ2300" manufactured by Sensofar Co., Ltd. In this case, in order to prevent the bending of the sample, an optically transparent adhesive is used, and the uneven surface is bonded to the glass substrate so as to have a surface, and then measured. At the time of measurement, the magnification of the objective lens was set to 50 times, and the resolution was lowered for measurement. This is because if the measurement is performed at a high resolution, the fine unevenness of the surface of the sample is also measured, and the counting of the convex portion is hindered.

(Arithmetic average height Pa at the profile curve, maximum profile height Pt, and average length PSm) Based on the measurement data obtained above, the arithmetic mean height Pa, the maximum profile height Pt, and the average length PSm are obtained by calculation according to JIS B 0601.

(number of convex parts) Based on the three-dimensional coordinate value of each point on the surface of the anti-glare film obtained in the above measurement, and based on the mechanism previously described with reference to FIG. 5, the presence of the region in the region of 200 μm × 200 μm is obtained. Number of convex parts the amount.

(Meaning the average area of the Morono polygon after the Molonoy split) Based on the 3-dimensional coordinate values of the points on the surface of the anti-glare film obtained in the above-mentioned measurement, and based on the mechanism previously described with reference to FIG. 5 and FIG. 6, the calculation is performed to obtain the Molinoyi. The average area of the polygon.

4. Evaluation of anti-glare performance of anti-glare film: (reflection, whitening, and visual evaluation of texture) In order to prevent reflection from the back surface of the anti-glare film, the black acryl resin sheet is bonded to the anti-glare film so that the uneven surface is a surface, and the concave-convex surface is exposed in a bright room irradiated with the fluorescent lamp. The side view was visually observed, and the presence or absence of the fluorescent light, the degree of whitening, and the texture were evaluated by visual observation. The reflection, whitening, and texture are evaluated by the following three stages of 1-3.

Reflection: 1: Unable to observe the reflection 2: Observing a slight reflection 3: Obviously observed

Whitening: 1: Unable to observe whitening 2: Observed a little white 3: Obviously observed whitening

Texture: 1: The surface is fine, the texture is good 2: The surface is slightly thick, the texture is slightly worse 3: The surface is obviously thick and the texture is poor.

(evaluation of glare) The glare is evaluated by the following method. That is, first, a photomask having a pattern of unit cells as shown in plan view in Fig. 9 is prepared. In the figure, the unit cell 40 is formed on a transparent substrate, and a groove-type chrome-shielding pattern 41 is formed with a line width of 10 μm, and a portion where the chrome-shielding pattern 41 is not formed is an opening portion. 42. Here, since the cell size is 254 μm × 84 μm (vertical × horizontal), the size of the opening is 244 μm × 74 μm (vertical × horizontal). The cell cells shown in the figure are arranged in a plurality of vertical and horizontal directions to form a photomask.

Then, as shown in the schematic cross-sectional view of Fig. 10, the chrome-shielding pattern 41 of the mask 43 is placed above, placed in a light box 45, and the anti-glare film 11 is adhered by an adhesive. The sample formed by bonding the glass sheet 41 to the surface of the uneven surface is placed on the mask 43. Among the light boxes 45, a light source 46 is disposed. In this state, visual observation is performed at a position 49 which is about 30 cm away from the sample, and the degree of glare is made in a 7-stage manner. Evaluation. Level 1 is a state in which glare is completely unrecognizable, level 7 is a state in which a severe glare is observed, and level 3 is a state in which only a few glare is observed.

(comparative evaluation) The polarizing plate on both sides of the front and back sides was peeled off from a liquid crystal television ("LC-42GX1W" manufactured by Sharp Co., Ltd.) which was sold in the market. In place of the original polarizing plates, the polarizing plate "Sumikalan SRDB831E" manufactured by Sumitomo Chemical Co., Ltd. is used on the back side and the surface side so that the respective absorption axes coincide with the absorption axes of the original polarizing plates. In the manner of bonding with an adhesive, and further on the display surface side polarizing plate, the antiglare film shown in each of the following examples is applied via an adhesive so that the uneven surface becomes a surface. Hehe. The LCD TV thus obtained is activated in a dark room, and the brightness of the black display state and the white display state is measured and calculated using the brightness meter "BM5A" type manufactured by TOPCON Co., Ltd. Out of contrast. Here, the contrast is expressed by the ratio of the brightness of the white display state with respect to the brightness of the black display state.

[Example 1]

(A) Preparation of embossing mold A copper ballard plating was applied to the surface of an iron drum (STKM13A by JIS) having a diameter of 200 mm. The copper ballard plating is made of a copper plating layer/thin silver plating layer/surface copper plating layer, and the total thickness of the plating layer is about 200 μm. The copper-plated surface was mirror-polished, and further, a zirconium bead "TZ-B53" manufactured by TOSOH Co., Ltd. was used at the polishing surface by using a sand blasting device (manufactured by Fujitsu Co., Ltd.). The product name, the average particle diameter is 53 μm), and the bead usage amount is 8 g/cm ² (unit surface area of the drum), the blasting pressure is 0.15 MPa (gauge pressure), and the distance from the nozzle for spraying the fine particles to the metal surface is 450 mm. Sandblasting and adding bumps on the surface. The obtained copper electroplated iron drum to which the unevenness was added was etched with a copper chloride aqueous solution. The amount of etching at this time was set to 8 μm. Then, chrome plating is performed to produce a mold for embossing. The thickness of the chromium plating at this time was set to 4 μm. The obtained mold had a Vickers hardness of 1000 on the surface.

(B) Manufacture of anti-glare film In the ethyl acetate, the following components were dissolved at a solid concentration of 60% to obtain an ultraviolet curable resin composition exhibiting a refractive index of 1.53 after curing.

(reaction product of hexamethylene diisocyanate and pentaerythritol triacrylate) leveling agent

In the ultraviolet curable resin composition, methyl methacrylate/styrene copolymer resin beads having an average particle diameter of 8 μm and a refractive index of 1.565 were added, and 25 parts were added to the ultraviolet curable resin 100 portion. Then, ethyl acetate was added so that the concentration of the solid portion (including the resin beads) became 50%, and the coating liquid was prepared.

The above-mentioned coating liquid was applied to a film of a cellulose triacetate (TAC) having a thickness of 80 μm so that the thickness of the dried coating film became 10 μm, and was allowed to stand for 3 minutes in a dryer set to 60 ° C. Dry. The dried film is pressed by a rubber roller so that the ultraviolet curable resin composition layer becomes the mold side at the uneven surface of the mold produced by (A), and is adhered to the film. . In this state, light from a high-pressure mercury lamp having a strength of 20 mW/cm ² is irradiated so that the amount of light converted into h-line becomes 200 mJ/cm ² from the TAC film side, so that the ultraviolet curable resin composition layer is formed. hardening. Then, the TAC film and the cured resin are integrally peeled off from the mold, and a transparent antiglare film made of a laminate of a cured resin having a concavity and convexity on the surface and a TAC film is obtained.

(C) Evaluation of anti-glare film With respect to the obtained antiglare film, the optical properties, the uneven surface shape, and the antiglare property were evaluated by the above-described methods, and as a result, the microparticles used in the production of the antiglare layer and the mold were produced. The types and quantities are shown together in Table 1. Also, a graph of the diffusion distribution is shown in FIG. 11, and a graph of the reflection distribution is shown in FIG. In addition, in Table 1, (A) is the sum of the amount of etching at the time of mold preparation, and the kind and quantity of the microparticles used for manufacture of an anti-glare layer, and (B) is the optical of an anti-glare film. The characteristics are summarized, and (C) is The surface shape and anti-glare properties of the anti-glare film were summarized. The details of the reflection sharpness in Table 1 (B) are as follows.

Reflective brightness 0.5mm optical comb: 1.4% 1.0mm optical comb: 5.4% 2.0mm optical comb: 9.6% total: 16.4%

[Example 2]

The amount of etching when the mold was produced was changed as in Table 1, and the other conditions were the same as in Example 1, whereby a mold for embossing having irregularities on the surface was produced. The obtained mold had a Vickers hardness of 1000 on the surface. Using this mold, a transparent antiglare film made of a laminate of a cured resin having a concavity and convexity and a TAC film on the surface was produced in the same manner as in Example 1.

[Examples 3 and 4]

The same type of the mold as in Example 1 was used, and the kind of fine particles used in the production of the antiglare layer and/or the amount of addition to the weight portion of the ultraviolet curable resin 100 was as shown in Table 1. The transparent antiglare film formed of a laminate of a cured resin having a concavity and convexity and a TAC film on the surface was produced in the same manner as in the first embodiment. In addition, the particles used in Example 3 The same is the same methyl methacrylate/styrene copolymer resin bead as in Example 1, and the microparticles used in Example 4 are polymethyl methacrylate having an average particle diameter of 8 μm and a refractive index of 1.490. Ester beads.

For the antiglare films obtained in Examples 2 to 4, the optical characteristics, surface shape, and antiglare property of these antiglare films are shown in Table 1 together with the data of Example 1. Further, the permeation diffusion distribution and the reflection distribution chart of the antiglare film are shown in Fig. 11 and Fig. 12 together with the data of the first embodiment.

[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 both were used as the ultraviolet curable resin not containing the resin beads. The composition was set to the same conditions as in Example 1, and a transparent antiglare film made of a laminate of a cured resin having a concavity and convexity on the surface and a TAC film was produced. The optical characteristics, surface shape, and antiglare property of the obtained antiglare film are shown in Table 1 together with the data of Example 1. Further, a graph of the transmission diffusion distribution of such anti-glare films is shown in FIG. 13, and a graph of the reflection distribution is shown in FIG.

As shown in Table 1, Examples 1 and 2 which satisfy the requirements of the present invention exhibit excellent anti-glare properties (low reflection and good texture) without glare or whitening, and are suitable for use in When the image display device is displayed, it also shows a high contrast. Further, in Examples 3 and 4 in which the internal haze was increased, although the comparison was slightly lower than that of Examples 1 and 2, it was found that the glare was more effective. On the other hand, in Comparative Examples 1 and 2, since the surface shape is almost the same as that of Examples 1 and 2, respectively, excellent anti-glare properties are exhibited, and whitening does not occur, and the contrast is also exhibited. There is a high value, but since at least one of the relative diffused light intensities T(20) and T(30) is lower than the specification of the present invention, the glare is strong, and when applied to an image display device, it is visually recognized. Sexuality has become a significant decrease.

Here, in Examples 1, 3, and 4 and Comparative Example 1, an anti-glare film was produced using the same mold, and in Example 2 and Comparative Example 2, an anti-glare film was produced using the same mold. On the other hand, the reflection characteristics of the antiglare film produced by using the same mold were almost the same, and as a result, it was found that the added fine particle system did not affect the surface shape.

[Comparative Examples 3 to 5]

In the ultraviolet curable resin composition (before the addition of the resin beads), which is the same as the user of the first embodiment, the porous fine particles 10 having an average particle diameter of about 10 μm and a refractive index of 1.46 are added to the ultraviolet curable resin 100. Further, in Comparative Examples 4 and 5, the average particle diameter of the general amount shown in Table 2 was added to the ultraviolet curable resin 100 portion. A porous microparticles of methyl methacrylate/styrene copolymer resin beads having a refractive index of 1.57 and having a refractive index of 1.57 are dispersed, and then the concentration of the solid component (including cerium microparticles and resin beads) is 30%. The ethyl acetate was added to prepare a coating liquid.

The above-mentioned coating liquid was applied to a film of a cellulose triacetate (TAC) having a thickness of 80 μm so that the thickness of the dried coating film was 4 μm, and it was allowed to stand for 3 minutes in a dryer set to 60 ° C. Dry. The light from the high-pressure mercury lamp having a strength of 20 mW/cm ² was irradiated so that the amount of light converted into h lines became 200 mJ/cm ² from the side of the photocurable resin composition layer of the film after drying to cure the ultraviolet rays. The resin composition layer is cured to obtain a transparent antiglare film made of a laminate of a cured resin having a concavity and convexity on the surface and a TAC film. In the antiglare film, as is apparent from the relationship between the particle diameter (about 10 μm) of the fine particles and the thickness of the coating film (4 μm), the fine particles protrude from the surface of the antiglare layer.

With respect to the obtained antiglare film, optical characteristics, uneven surface shape, and antiglare property were evaluated by the above-described methods, and the results were shown together with the composition of the resin in Table 2. In Table 2, (A) is a summary of the fine particles to be incorporated in the curable resin, (B) is the induction of the optical characteristics of the anti-glare film, and (C) is the prevention of the anti-glare film. The surface shape and anti-glare properties of the glare film were summarized. Again, a graph of the diffusion distribution is shown in Figure 15, and a graph of the reflection distribution is shown in Figure 16.

As shown in Table 2, in Comparative Example 3, since the relative diffused light intensities T(20) and T(30) are lower than the specifications of the present invention, although the contrast system is not lowered, the glare is strong. When applied to an image display device, the visibility is significantly impaired. In Comparative Example 4, since the relative diffused light intensity T(20) at 20 ∘ incident is higher than the specification of the present invention, the contrast is reduced to 1800 or less, which is a loss of visibility.

Further, in the surface shape, the average length PSm is large, and the number of convex portions is small, and the average area of the Molino poly polygon is large, and as a whole, it is defined in the present invention. The larger the shape, therefore, even if the diffused light system is strong, it is impossible to suppress the glare. In Comparative Example 5, since the relative diffused light intensities T(20) and T(30) greatly exceeded the requirements of the present invention, the glare did not occur, but the contrast was greatly reduced. Further, in Comparative Examples 3 to 5, the average length PSm is generally large, and the average area of the Molino Poly is more than the specification of the present invention, and the number of the convex portions is lower than the specification of the present invention. As a result, the texture is rough and has a convex appearance.

[Comparative Examples 6 to 9]

An anti-glare film "AG3", "AG5", and "SL6" which are used as an anti-glare layer for the polarizing plate "SUMIKALAN" sold by Sumitomo Chemical Co., Ltd., and which are filled with a filler in the ultraviolet curable resin. "CV2" (Comparative Examples 6 to 9, respectively) were evaluated for respective optical characteristics, surface shape, and antiglare performance by the above-described methods, and the results are shown in Table 3. In Table 3, (B) is the optical of the anti-glare film. The characteristics were summarized, and (C) was summarized for the surface shape and anti-glare properties of the anti-glare film. Again, a graph of the diffusion distribution is shown in Figure 17, and a graph of the reflection distribution is shown in Figure 18.

In Comparative Example 6, since the relative diffused light intensity T(20) and T(30) are lower than the specification of the present invention, although the contrast system is not lowered, the glare is strong and the visibility is remarkably lowered. . Moreover, since the requirements of the surface shape are completely out of the provisions of the present invention, the texture is not good, and there is a convex appearance. In Comparative Example 7, since the relative diffused light intensity T(30) at 30 ∘ incidence was lower than the specification of the present invention, it was a result of glare. In Comparative Example 8 and Comparative Example 9, since the relative diffused light intensities T(20) and T(30) were generally large, the glare did not occur, but the contrast was greatly reduced. Further, in Comparative Example 8, since the reflectance R (40) and R (50) is also the line exceeds a predetermined value of the present invention, therefore, the whole screen is whitish system, and produce whitened.

From the above results, it is understood that the balance of the requirements specified in the present invention is excellent, and it is important to achieve the optical characteristics which are the object of the present invention.

[Industrial use possibility]

The anti-glare film of the present invention exhibits excellent anti-glare properties and also prevents deterioration of visibility due to whitening, and does not cause glare when disposed on the surface of a high-definition image display device. The situation can achieve high contrast. The anti-glare polarizing plate in which the anti-glare film and the polarizing element are combined exhibits the same effect. On the other hand, the image display device in which the anti-glare film of the present invention or the anti-glare polarizing plate is disposed has high anti-glare performance and is excellent in visibility.

The anti-glare film of the present invention is disposed on the liquid crystal panel, the plasma display panel, the CRT display, the organic EL display, etc., by making the anti-glare film more visible than the image display device. The display can be made without blushing and glare, and can lighten the image of the image, and can be used to give excellent visibility.

11‧‧‧Anti-glare film

12‧‧‧ Film normal

13‧‧‧ Direction of incident light when measured by diffused light intensity

14‧‧‧Determination of the transmitted light intensity (normal direction)

15‧‧‧Indirect light direction when measuring reflectance

16‧‧‧reflective direction

17‧‧‧Arbitrary reflection direction

19‧‧‧ contains the direction of incident light and the normal of the film

‧‧‧The angle of incidence when measuring the intensity of transmitted light

θ‧‧‧Reflection angle when measuring reflectance

21‧‧‧any point on the anti-glare film

22‧‧‧Anti-glare film surface

23‧‧‧Film datum

24‧‧‧Projection surface of the circle-to-film reference plane centered on any point on the anti-glare film

26‧‧‧Projection point of the apex of the convex part (the mother point of the division of Molonoyi)

27‧‧‧Molonoi polygon

28‧‧‧Molonoy polygons that are not calculated in the mean and are adjacent to the boundary of the measured field of view

31‧‧‧Metal substrate

32‧‧‧ copper or nickel plating

33‧‧‧Grinding surface

34‧‧‧Concave surface formed by impact of particles

35‧‧‧ copper plating

36a‧‧‧The surface of the concave and convex surface formed by the impact of fine particles by etching

36b‧‧‧The surface of the concave and convex surface formed by the impact of fine particles by copper plating

37‧‧‧Chromium plating

38‧‧‧Recessed surface remaining after chrome plating

39‧‧‧Flat surface produced by grinding the surface after chrome plating

40‧‧‧Units of the mask

41‧‧‧Cream chrome shade pattern

42‧‧‧ Opening of the mask

43‧‧‧Photomask

45‧‧‧Lighting box

46‧‧‧Light source

47‧‧‧ glass plate

49‧‧‧Looking position

[Fig. 1] When the light is incident from the transparent support side of the anti-glare film and the intensity of the diffused light observed in the normal direction of the anti-glare layer side is taken out, the direction of light incident and the direction of the transmitted diffused light intensity are measured. A perspective view of a model presentation.

[Fig. 2] An example of a graph in which the incident angle is changed and the measured relative diffused light intensity (logarithmic scale) is plotted against the incident angle.

FIG. 3 is a perspective view schematically showing an incident direction and a reflection direction of light from the anti-glare layer side of the reflectance.

[Fig. 4] An example of a graph in which a reflection angle and a reflectance (reflectance is a logarithmic scale) of reflected light of light incident at an angle of 30 Å from the normal line of the anti-glare film are plotted.

Fig. 5 is a perspective view showing a machine making mode for determining a convex portion of an anti-glare film.

[Fig. 6] shows a Molono diagram of the example of the partition of Molino.

Fig. 7 is a schematic cross-sectional view showing a method of manufacturing a mold for producing an antiglare film of the present invention in various works.

Fig. 8 is a schematic cross-sectional view showing a state in which the surface is polished after chrome plating.

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

Fig. 10 is a schematic cross-sectional view showing the state of glare evaluation.

Fig. 11 is a graph showing the transmission diffusion distribution of the antiglare film obtained in Examples 1 to 4.

Fig. 12 is a graph showing the reflection distribution of the antiglare film obtained in Examples 1 to 4.

Fig. 13 is a graph showing the transmission diffusion distribution of the antiglare film obtained in Comparative Examples 1 and 2.

Fig. 14 is a graph showing the reflection distribution of the antiglare film obtained by Comparative Examples 1 and 2.

Fig. 15 is a graph showing the transmission diffusion distribution of the antiglare film obtained in Comparative Examples 3 to 5.

Fig. 16 is a graph showing the reflection distribution of the antiglare film obtained in Comparative Examples 3 to 5.

Fig. 17 is a graph showing the transmission diffusion distribution of the antiglare film used in Comparative Examples 6 to 9.

Fig. 18 is a graph showing the reflection distribution of the antiglare film used in Comparative Examples 6 to 9.

11‧‧‧Anti-glare film

12‧‧‧ Film normal

13‧‧‧ Direction of incident light when measured by diffused light intensity

14‧‧‧Determination of the transmitted light intensity (normal direction)

19‧‧‧ contains the direction of incident light and the normal of the film

Claims (10)

An anti-glare film is an anti-glare film on which an anti-glare layer having a fine uneven surface is formed on a transparent support, and is characterized in that when light is incident from the transparent support side at an incident angle of 20° The relative diffused light intensity T(20) at the normal direction of the anti-glare layer is 0.0001% or more and 0.0005% or less, and when the light is incident from the transparent support side at an incident angle of 30°, the anti-glare layer is formed. The relative diffused light intensity T(30) at the side normal direction is 0.00004% or more and 0.00025% or less. When light is incident from the antiglare layer side at an incident angle of 30°, the reflectance R of the reflection angle of 30° ( 30) is 0.05% or more and 2% or less, the reflectance R (40) of the reflection angle of 40° is 0.0001% or more and 0.005% or less, and the reflectance R (50) of the reflection angle of 50° is 0.00001% or more and 0.0005% or less. The haze of the vertical incident light is 0.1% or more and 5% or less, and the total haze is 5% or more and 25% or less. The anti-glare film according to claim 1, wherein three types of optical combs having a width of 0.5 mm, 1.0 mm, and 2.0 mm in a dark portion and a bright portion are used and measured at an incident angle of light of 45°. The sum of the reflection sharpness is 40% or less. The anti-glare film according to the first aspect of the invention, wherein the arithmetic mean height Pa of the cross-sectional curve constituting the uneven surface of the anti-glare layer is 0.05 μm or more and 0.2 μm or less, and the maximum cross-sectional height Pt is 0.2 μm or more and 1 μm or less, and the average length PSm is 15 μm or more and 30 μm or less. The antiglare film according to the first aspect of the invention, wherein the uneven surface constituting the antiglare layer is provided with 50 or more and 100 or less convex portions in a region of 200 μm × 200 μm. The anti-glare film according to the first aspect of the invention, wherein the apex of the convex portion constituting the uneven surface of the anti-glare layer is used as a mother point, and the surface is subjected to voronoi tessellation. The average area of the formed polygonal shape is 100 μm ² or more and 1000 μm ² or less. The anti-glare film according to the first aspect of the invention, wherein the surface unevenness of the anti-glare layer is formed by transfer of a mold having a concave-convex surface, and the anti-glare layer is 100% by weight relative to the adhesive resin. The part contains 10 to 100 parts by weight of fine particles having an average particle diameter of 5 μm or more and 15 μm or less and a refractive index difference between the bonding resin and the bonding resin of 0.01 or more and 0.06 or less. The anti-glare film according to claim 6, wherein the fine particles are completely buried in the anti-glare layer and do not affect the surface shape. The anti-glare film according to the first aspect of the invention, wherein the anti-glare layer has a low-reflection film formed on the uneven surface of the anti-glare layer. An anti-glare polarizing plate characterized in that a polarizing element is bonded to a transparent support side of the anti-glare film, and an anti-glare as described in any one of claims 1 to 8. film. An image display device comprising: anti-glare as described in any one of claims 1 to 8; a film or an anti-glare polarizing plate according to claim 9; and an image display element, wherein the anti-glare film or the anti-glare polarizing plate is disposed on the outer side of the anti-glare layer The image shows the viewing side of the component.