TWI834758B - Anti-glare film, manufacturing method of anti-glare film, optical component and image display device - Google Patents

Abstract

An object of the present invention is to provide an anti-glare film in which the generation of white fog is suppressed. The solution is an anti-glare film, which is laminated with an anti-glare layer (B) on a translucent base material (A). It is characterized by: The anti-glare layer (B) side of the anti-glare film has irregularities formed on its outermost surface, and The aforementioned concavity and convexity satisfy the following mathematical formulas (1) and (2): θa≦0.24　　　　　(1) Rz≦0.20　　　　　(2) In the aforementioned mathematical formula (1), θa is the average inclination angle [°] of the aforementioned concavity and convexity, In the aforementioned mathematical formula (2), Rz represents the ten-point average height [μm] of the aforementioned concavities and convexities.

Description

Anti-glare film, manufacturing method of anti-glare film, optical component and image display device

The present invention relates to an anti-glare film, a manufacturing method of the anti-glare film, an optical component and an image display device.

For various image display devices such as cathode tube display devices (CRT), liquid crystal display devices (LCD), plasma display panels (PDP) and electroluminescent displays (ELD), anti-glare treatment is performed to prevent the aforementioned The surface of the image display device is reduced in contrast due to the reflection of external light such as fluorescent lamps or sunlight or the reflection of the image. Especially with the development of large-scale image display devices, the number of image display devices equipped with anti-glare films is also increasing. big.

There are many documents describing anti-glare films, such as Patent Documents 1 and 2.

Prior technical literature patent documents Patent Document 1: Japanese Patent Application Publication No. 2009-109683 Patent Document 2: Japanese Patent Application Publication No. 2003-202416

The problem to be solved by the invention For anti-glare films, when a light source is reflected, a chromatic aberration in the form of black and white waves (hereinafter referred to as "white haze") may occur. For displays (image display devices) using anti-glare films, if white fog is generated significantly, the appearance quality may be reduced.

Therefore, an object of the present invention is to provide an anti-glare film in which the generation of white fog is suppressed, a manufacturing method of the anti-glare film, an optical member, and an image display device.

means to solve problems In order to achieve the aforementioned objects, the first anti-glare film of the present invention, An anti-glare layer (B) laminated on a translucent base material (A) is characterized by: In the anti-glare film, unevenness is formed on the outermost surface of the anti-glare layer (B) side, and The aforementioned concavities and convexities satisfy the following mathematical formulas (1) and (2). θa≦0.24　　　　　(1) Rz≦0.20　　　　　(2) In the aforementioned mathematical formula (1), θa is the average inclination angle [°] of the aforementioned concavity and convexity, In the aforementioned mathematical formula (2), Rz represents the ten-point average height [μm] of the aforementioned concavities and convexities.

In order to achieve the aforementioned object, the second anti-glare film of the present invention, The anti-glare layer (B) and other layers are sequentially laminated on the translucent base material (A), and are characterized by: Concave and convex are formed on the outermost surface of the aforementioned other layers, and The aforementioned concavities and convexities satisfy the following mathematical formulas (1) and (2). In addition, below, the 1st and 2nd anti-glare film of this invention may be collectively called "the anti-glare film of this invention". θa≦0.24　　　　　(1) Rz≦0.20　　　　　(2) In the aforementioned mathematical formula (1), θa is the average inclination angle [°] of the aforementioned concavity and convexity, In the aforementioned mathematical formula (2), Rz represents the ten-point average height [μm] of the aforementioned concavities and convexities.

The manufacturing method of the anti-glare film of the present invention is characterized by comprising the following steps: The step of forming the anti-glare layer (B) is to form the anti-glare layer (B) on the aforementioned translucent base material (A); and The unevenness forming step is to form the unevenness on the outermost surface of the anti-glare layer (B) side of the anti-glare film in a manner that satisfies the aforementioned mathematical formulas (1) and (2); The anti-glare layer (B) forming step includes: a coating step of applying a coating liquid on the translucent base material (A); and a coating film forming step of drying the applied coating liquid. form a coating film; and The aforementioned coating liquid contains resin and solvent.

The optical member of the present invention is an optical member containing the anti-glare film of the present invention.

The image display device of the present invention is an image display device including the anti-glare film of the present invention or the optical member of the present invention.

Invention effect According to the present invention, it is possible to provide an anti-glare film in which the generation of white fog is suppressed, a manufacturing method of the anti-glare film, an optical member, and an image display device.

Next, the present invention will be further explained in detail using examples. However, the present invention is not limited by the following description.

The anti-glare film of the present invention can, for example, further satisfy the following mathematical formula (3). Ra≦0.050　　　　　　　　　　　　　(3) In the above mathematical formula (3), Ra is the arithmetic mean surface roughness [μm] of the above concavities and convexities.

For example, the anti-glare film of the present invention may be laminated with another layer on the surface of the anti-glare layer (B) opposite to the light-transmitting base material (A). The aforementioned other layers may also be, for example, low-reflective layers.

In the anti-glare film of the present invention, for example, the anti-glare layer (B) may also contain a binder resin and a cohesive filler. The agglomerative filler may be, for example, organoclay.

In the anti-glare film of the present invention, for example, the anti-glare layer (B) may not contain particles.

In the manufacturing method of the anti-glare film of the present invention, for example, the step of forming the anti-glare layer (B) may further include a hardening step of hardening the coating film.

In the manufacturing method of the anti-glare film of the present invention, for example, the aforementioned solvent may also include toluene and methyl ethyl ketone.

In the manufacturing method of the anti-glare film of the present invention, for example, the anti-glare film is an anti-glare film including the other layer, and the unevenness forming step may also include forming the other layer on the anti-glare layer (B). The other layer formation steps of the layer.

The optical member of the present invention may also be a polarizing plate, for example.

[1. Anti-glare film] The first anti-glare film of the present invention has an anti-glare layer (B) laminated on a translucent base material (A) as described above, and is characterized in that the anti-glare layer (B) in the anti-glare film The outermost surface of the ) side is formed with unevenness, and the unevenness satisfies the following mathematical formulas (1) and (2). θa≦0.24　　　　　(1) Rz≦0.20　　　　　(2) In the aforementioned mathematical formula (1), θa is the average inclination angle [°] of the aforementioned concavity and convexity, In the aforementioned mathematical formula (2), Rz represents the ten-point average height [μm] of the aforementioned concavities and convexities.

As mentioned above, the second anti-glare film of the present invention has an anti-glare layer (B) and other layers sequentially laminated on the translucent base material (A), and is characterized in that an anti-glare layer (B) and other layers are formed on the outermost surface of the other layers. The unevenness satisfies the following mathematical formulas (1) and (2). θa≦0.24　　　　　(1) Rz≦0.20　　　　　(2) In the aforementioned mathematical formula (1), θa is the average inclination angle [°] of the aforementioned concavity and convexity, In the aforementioned mathematical formula (2), Rz represents the ten-point average height [μm] of the aforementioned concavities and convexities.

Figure 1 is a cross-sectional view showing an example of the structure of the anti-glare film of the present invention. As shown in the figure, the anti-glare film 10 has an anti-glare layer (B) 12 laminated on one area of the translucent base material (A) 11 . The anti-glare layer (B) 12 contains particles 12b and a thixotropy imparting agent 12c in the resin layer 12a. A low-reflection layer (C) 13 is further laminated on the surface of the anti-glare layer (B) 12 on the opposite side to the translucent base material (A) 11 as the aforementioned other layer. In the anti-glare film 10, the outermost surface on the side of the anti-glare layer (B) 12 (the surface of the low-reflective layer (C) 13 on the side opposite to the translucent base material (A) 11) is formed with irregularities. The average inclination angle θa of the unevenness is 0.24° or less as mentioned above, and the ten-point average height (also called ten-point average roughness or ten-point average surface roughness) Rz of the unevenness is 0.20 μm or less as mentioned above. However, the anti-glare film of the present invention is not limited to this. For example, the particles 12b, the thixotropic agent 12c and the other layer (low-reflective layer (C)) 13 may be optional.

Figure 2 is a cross-sectional view showing another example of the structure of the anti-glare film of the present invention. As shown in the figure, the composition of the anti-glare film 10 is the same as the anti-glare film 10 in FIG. 1 except that there is no other layer (low reflection layer (C)) 13 . In addition, in the anti-glare film 10 of FIG. 2, an anti-glare layer (B) 12 is formed on the outermost surface (the surface of the anti-glare layer (B) 12 on the opposite side to the translucent base material (A) 11). There are bumps. The average inclination angle θa of the unevenness is 0.24° or less, and the ten-point average height Rz of the unevenness is 0.20 μm or less.

Figure 3 is a cross-sectional view showing yet another example of the structure of the anti-glare film of the present invention. As shown in the figure, the composition of the anti-glare film 10 is the same as that of Figure 1 except that the anti-glare layer (B) 12 does not contain particles 12b. In addition, the cross-sectional view of FIG. 4 shows yet another example of the structure of the anti-glare film of the present invention. As shown in the figure, the composition of the anti-glare film 10 is the same as that of Figure 2 except that the anti-glare layer (B) 12 does not contain particles 12b.

In addition, in the anti-glare film of the present invention, "the outermost surface on the anti-glare layer (B) side" is the outermost surface on the anti-glare layer (B) side. Specifically, "the outermost surface on the side of the anti-glare layer (B)" is the layer between the aforementioned anti-glare layer (B) and the aforementioned translucent base material (A) when there is no other layer mentioned above (for example, Figures 2 and 4). The surface on the opposite side. In addition, "the outermost surface on the side of the anti-glare layer (B)" when there is the aforementioned other layer (for example, Figures 1 and 3), is the combination of the aforementioned other layer (in Figures 1 and 3, the low-reflective layer (C) 13) and the aforementioned The outermost surface of the side opposite to the translucent base material (A).

The anti-glare film of the present invention has excellent anti-glare properties even if θa and Rz are small and the unevenness of the outermost surface is gentle, and as mentioned above, the generation of white fog can be suppressed. Especially for general anti-glare films, when a low-reflective layer is provided on the anti-glare layer, the generation of white fog may become more noticeable. However, as long as the anti-glare film of the present invention is used, for example, even when a low-reflective layer (C) is provided on the anti-glare layer (B), the generation of white fog can still be suppressed.

In addition, in FIGS. 1 and 3 , the other layer is the low-reflective layer (C) 13. However, the other layer in the anti-glare film of the present invention is not limited to the low-reflective layer. The aforementioned other layers may be, for example, a low refractive index layer, a low reflection layer, a conductive layer, an antifouling layer, a high hardness layer, a high refractive index layer, a UV absorbing layer, etc. The aforementioned other layers may be one layer or multiple layers. When there are multiple layers, they may be one type or multiple types. For example, the aforementioned other layers may be optical films whose thickness and refractive index are strictly controlled, or may be laminated with two or more layers of the aforementioned optical films.

In the anti-glare film of the present invention, as described above, the average inclination angle θa (°) of the uneven shape of the outermost surface of the anti-glare layer (B) is 0.24 or less. The average inclination angle θa may be, for example, 0.23° or less, 0.20° or less, or 0.19° or less. The lower limit of the average inclination angle θa is not particularly limited. For example, it may be a value greater than or equal to 0°, or may be greater than 0.10°, greater than 0.11°, greater than 0.13°, or greater than 0.15°. The average inclination angle θa may be, for example, more than 0° and less than 0.23°, more than 0.10° and less than 0.23°, more than 0.11° and less than 0.23°, more than 0.13° and less than 0.23°, more than 0.15° and less than 0.23°, more than 0 ° and below 0.20°, above 0.10° and below 0.20°, above 0.11° and below 0.20°, above 0.13° and below 0.20°, above 0.15° and below 0.20°, above 0° and below 0.19°, 0.10° Above and below 0.19°, above 0.11° and below 0.19°, above 0.13° and below 0.19°, or above 0.15° and below 0.19°. Here, the aforementioned average inclination angle θa is a value defined by the following mathematical formula (3). The average inclination angle θa can be measured, for example, by the method described in the Examples described below. Average inclination angle θa=tan ^-1 Δa (3)

In the aforementioned mathematical formula (3), Δa is represented by the following mathematical formula (4), which is the lowest value between the peaks and valleys of adjacent peaks in the reference length L of the thickness curve specified in JIS B 0601 (1994 edition). The value obtained by dividing the total of point differences (height h) (h1＋h2＋h3・・・＋hn) by the above-mentioned reference length L. The aforementioned roughness curve is a curve obtained by removing surface undulation components longer than a predetermined wavelength from the cross-sectional curve using a phase difference compensation type high-pass filter. In addition, the aforementioned cross-sectional curve is the outline of the cut surface after the object surface is cut with a plane at right angles to the object surface. Δa＝(h1+h2+h3・・・+hn)/L　(4)

Furthermore, in the anti-glare film of the present invention, as described above, the uneven shape of the outermost surface on the anti-glare layer (B) side has a ten-point average height Rz of the uneven surfaces of 0.20 μm or less. The ten-point average height Rz may be, for example, 0.19 μm or less or 0.18 μm or less. The lower limit of the ten-point average height Rz is not particularly limited. For example, it may be 0 μm or more, or 0.10 μm or more, 0.12 μm or more, 0.13 μm or more, or 0.17 μm or more. The ten-point average height Rz may be, for example, more than 0 μm and less than 0.20 μm, more than 0.10 μm and less than 0.20 μm, more than 0.12 μm and less than 0.20 μm, more than 0.13 μm and less than 0.20 μm, more than 0.17 μm and less than 0.20 μm, more than 0.17 μm and less than 0.20 μm. 0 μm and below 0.19 μm, 0.10 μm and below 0.19 μm, 0.12 μm and below 0.19 μm, 0.13 μm and below 0.19 μm, 0.17 μm and below 0.19 μm, above 0 μm and below 0.18 μm, and above 0.10 μm And 0.18 μm or less, 0.12 μm or more and 0.18 μm or less, 0.13 μm or more and 0.18 μm or less, or 0.17 μm or more and 0.18 μm or less. The aforementioned ten-point average height Rz can be measured, for example, as described in the Examples described below.

The arithmetic mean surface roughness (also called arithmetic mean height) Ra of the uneven shape of the outermost surface of the anti-glare layer (B) is not particularly limited, but may be 0.050 μm or less as mentioned above, for example. The arithmetic mean surface roughness Ra may be, for example, 0.048 μm or less, 0.045 μm or less, or 0.043 μm or less. The lower limit of the arithmetic mean surface roughness Ra is not particularly limited. For example, it is a value of 0 μm or more, and may be 0.010 μm or more, 0.020 μm or more, 0.030 μm or more, or 0.035 μm or more. The arithmetic mean surface roughness Ra may be, for example, more than 0 μm and less than 0.050 μm, more than 0.010 μm and less than 0.050 μm, more than 0.020 μm and less than 0.050 μm, more than 0.030 μm and less than 0.050 μm, more than 0.035 μm and less than 0.050 μm, More than 0 μm and less than 0.048 μm, more than 0.010 μm and less than 0.048 μm, more than 0.020 μm and less than 0.048 μm, more than 0.030 μm and less than 0.048 μm, more than 0.035 μm and less than 0.048 μm, more than 0 μm and less than 0.045 μm, 0.010 μm Above and below 0.045 μm, above 0.020 μm and below 0.045 μm, above 0.030 μm and below 0.045 μm, above 0.035 μm and below 0.045 μm, above 0 μm and below 0.043 μm, above 0.010 μm and below 0.043 μm, above 0.020 μm and below 0.043 μm or less, 0.030 μm or more and 0.043 μm or less, or 0.035 μm or more and 0.043 μm or less. In order to prevent external light or image reflection on the surface of the anti-glare hard-coated film, the surface should be roughened to a certain extent, that is, Ra should be large to a certain extent. If the Ra is within the above range, for example, when used in an image display device, the scattering of reflected light when viewed from an oblique direction is suppressed, thereby improving white halo and improving contrast in bright areas. In addition, in the present invention, the aforementioned "arithmetic mean surface roughness Ra" adopts the arithmetic mean surface roughness Ra specified in JIS B 0601 (1994 edition).

The average distance Sm (mm) between the concave and convex shapes on the outermost surface of the anti-glare layer (B) is not particularly limited, but may be in the range of 0.025 to 0.275, for example. Thereby, for example, an anti-glare hard-coat film that is excellent in anti-glare properties and can prevent whitening can be produced. In the present invention, the average distance Sm (mm) between concave and convex on the surface of the anti-glare layer (B) is the average distance Sm (mm) between concavities and convexes measured in accordance with JIS B0601 (1994 edition). The aforementioned Sm may be, for example, 0.050 mm or more, 0.075 mm or more, 0.100 mm or more, or 0.125 mm or more, and may be 0.250 mm or less, 0.225 mm or less, 0.200 mm or less, or 0.175 mm or less. The aforementioned Sm may be, for example, 0.050 mm or more and 0.250 mm or less, 0.050 mm or more and 0.225 mm or less, 0.050 mm or more and 0.200 mm or less, 0.050 mm or more and 0.175 mm or less, 0.075 mm or more and 0.250 mm or less, 0.075 mm or more and 0.225 mm. mm or less, 0.075mm or more and 0.200mm or less, 0.075mm or more and 0.175mm or less, 0.100mm or more and 0.250mm or less, 0.100mm or more and 0.225mm or less, 0.100mm or more and 0.200mm or less, 0.100mm or more and 0.175mm or less , 0.125mm or more and 0.250mm or less, 0.125mm or more and 0.225mm or less, 0.125mm or more and 0.200mm or less, or 0.125mm or more and 0.175mm or less.

The haze value of the anti-glare film of the present invention is not particularly limited, and may be in the range of 0 to 10%, for example. The aforementioned haze value is the overall haze value (opacity) of the anti-glare film in compliance with JIS K 7136 (2000 edition). The aforementioned haze value is preferably in the range of 0~5%, and more preferably in the range of 0~3%. In order to set the haze value within the above range, it is preferable to select the particles and the resin so that the difference in refractive index between the particles and the resin falls within the range of 0.001 to 0.02. By setting the haze value within the aforementioned range, a clear image can be obtained and the contrast in dark places can be improved.

Hereinafter, further examples will be given for the above-mentioned translucent base material (A), the above-mentioned anti-glare layer (B) and the above-mentioned other layers respectively. In addition, the following description mainly focuses on the case where the anti-glare layer (B) is an anti-glare hard coat layer and the other layer is a low-reflective layer (C), but the present invention is not limited thereto.

The aforementioned translucent base material (A) is not particularly limited, and examples thereof include transparent plastic film base materials and the like. The aforementioned transparent plastic film base material is not particularly limited. It should be one with good visible light transmittance (preferably the transmittance is above 90%) and good transparency (preferably the haze value is below 1%). Examples can be given Such as the transparent plastic film base material recorded in Japanese Patent Application Publication No. 2008-90263. As the aforementioned transparent plastic film base material, one with less optical birefringence can be suitably used. The anti-glare film of the present invention can also be used as a protective film for polarizing plates, for example. In this case, the transparent plastic film base material is preferably made of triacetyl cellulose (TAC), polycarbonate, acrylic polymer, cyclic Or films formed from polyolefins with norbornene structure. Furthermore, in the present invention, as will be described later, the transparent plastic film base material may also be the polarizer itself. With the above structure, a protective layer made of TAC or the like is not required and the structure of the polarizing plate can be simplified. Therefore, the number of manufacturing steps of the polarizing plate or the image display device can be reduced, thereby improving production efficiency. Furthermore, as long as it has the above-mentioned structure, the polarized light can be made into a thinner layer. In addition, when the transparent plastic film base material is a polarizer, the anti-glare layer (B) and the low-reflective layer (C) will function as a protective layer. Moreover, as long as it has the above-described structure, the anti-glare film can also serve as a cover plate when attached to the surface of a liquid crystal cell, for example.

In the present invention, the thickness of the aforementioned translucent base material (A) is not particularly limited. Taking into consideration the workability such as strength, handleability, and thin-layer properties, it is, for example, 10 to 500 μm, 20 to 300 μm, or 30 to 30 μm. 200μm range. The refractive index of the translucent base material (A) is not particularly limited. The aforementioned refractive index is, for example, in the range of 1.30 to 1.80 or 1.40 to 1.70.

In the anti-glare film of the present invention, for example, the resin contained in the translucent base material (A) may also contain an acrylic resin.

In the anti-glare film of the present invention, for example, the translucent base material (A) may be an acrylic film.

In the anti-glare film of the present invention, for example, the anti-glare layer (B) may also contain resin and filler. The aforementioned filler may also include at least one of particles and a thixotropic agent.

For example, the anti-glare layer (B) contains no particles and contains a thixotropy-imparting agent, so that the anti-glare film of the present invention can be produced in which the θa and Rz are small and the unevenness of the outermost surface is gentle. Furthermore, when the anti-glare layer (B) contains a thixotropy imparting agent and particles with a small particle size, the anti-glare film of the present invention can be produced in which the θa and Rz are small and the unevenness of the outermost surface is gentle.

In the anti-glare film of the present invention, for example, the resin contained in the anti-glare layer (B) may also contain acrylate resin (also called acrylic resin).

In the anti-glare film of the present invention, for example, the resin contained in the anti-glare layer (B) may also contain urethane acrylate resin.

In the anti-glare film of the present invention, for example, the resin contained in the anti-glare layer (B) may be a copolymer of a hardened urethane acrylate resin and a multifunctional acrylate.

In the anti-glare film of the present invention, for example, the anti-glare layer (B) is formed using an anti-glare layer-forming material containing a resin and a filler, and the anti-glare layer (B) may have an aggregation part, and the aggregation part is The filler agglomerates to form convex portions on the surface of the anti-glare layer (B). Moreover, in the aggregation part which forms the said convex part, the said filler may exist in the state in which a plurality of fillers are gathered in one direction in the plane direction of the said anti-glare layer (B). For example, in the image display device of the present invention, the anti-glare film of the present invention may be arranged so that the direction in which the plurality of fillers are gathered coincides with the long side direction of the black matrix pattern.

In the anti-glare film of the present invention, the thixotropy-imparting agent may be, for example, at least one member selected from the group consisting of organoclay, oxidized polyolefin, and modified urea. Moreover, the thixotropy-imparting agent may be, for example, a thickening agent.

The anti-glare film of the present invention preferably contains the thixotropy-imparting agent in the range of, for example, 0.2 to 5 parts by weight relative to 100 parts by weight (mass) of the resin in the anti-glare layer (B).

The anti-glare film of the present invention preferably contains the particles in the range of, for example, 0.2 to 12 parts by weight or 0.5 to 12 parts by weight based on 100 parts by weight of the resin in the anti-glare layer (B).

In the manufacturing method of the anti-glare film of the present invention, the surface shape of the anti-glare film can be adjusted by adjusting the weight part of the particles in the anti-glare layer forming material relative to 100 parts by weight of the resin.

By having an aggregation part in which particles are agglomerated, for example, the anti-glare film of the present invention can be produced in which the uneven shape of the anti-glare film is gentle. Furthermore, for example, by having the agglomeration portion, the average unevenness distance Sm (mm) on the surface of the anti-glare layer (B) becomes larger. The anti-glare film with the above-mentioned surface shape can effectively prevent reflection of fluorescent lamps and the like. However, the anti-glare film of the present invention is not limited to this.

The anti-glare layer (B) is formed as a coating film by applying a coating liquid containing the resin, the paint and the solvent to at least one side of the translucent base material (A), as will be described later, and then, The coating film is formed by removing the solvent. Examples of the resin include thermosetting resins and free radiation-curing resins curable by ultraviolet rays or light. Commercially available thermosetting resin, ultraviolet curing resin, etc. can also be used as the aforementioned resin.

As the thermosetting resin or ultraviolet curing resin, for example, a curing compound having at least one of an acrylate group and a methacrylate group that can be cured by heat, light (ultraviolet, etc.) or electron rays can be used. Examples include polysilicone resin, polyester resin, polyether resin, epoxy resin, urethane resin, alkyd resin, spiroacetal resin, polybutadiene resin, polythiol polyene resin, and polyol. Oligomers or prepolymers of polyfunctional compounds such as acrylate or methacrylate. These may be used individually by 1 type or in combination of 2 or more types.

For example, a reactive diluent having at least one of an acrylate group and a methacrylate group can be used in the aforementioned resin. Examples of the reactive diluent include those described in Japanese Patent Application Laid-Open No. 2008-88309, and include, for example, monofunctional acrylates, monofunctional methacrylates, polyfunctional acrylates, polyfunctional methacrylates, and the like. The reactive diluent is preferably a trifunctional or higher acrylate or a trifunctional or higher methacrylate. This is because the anti-glare layer (B) can have excellent hardness. Examples of the reactive diluent include butanediol glyceryl ether diacrylate, isocyanuric acid acrylate, isocyanuric acid methacrylate, and the like. These may be used individually by 1 type or in combination of 2 or more types.

The main functions of the particles used to form the anti-glare layer (B) are to make the surface of the anti-glare layer (B) formed into a concave and convex shape to impart anti-glare properties and to control the fog of the anti-glare layer (B). degree value. The haze value of the anti-glare layer (B) can be designed by controlling the refractive index difference between the particles and the resin. Examples of the particles include inorganic particles and organic particles. The inorganic particles are not particularly limited, and examples thereof include silicon oxide particles, titanium oxide particles, aluminum oxide particles, zinc oxide particles, tin oxide particles, calcium carbonate particles, barium sulfate particles, talc particles, kaolin particles, calcium sulfate particles, and the like. In addition, the aforementioned organic particles are not particularly limited, and examples thereof include polymethyl methacrylate resin powder (PMMA particles), polysilicone resin powder, polystyrene resin powder, polycarbonate resin powder, and acrylic styrene resin powder. Benzoguanamine resin powder, melamine resin powder, polyolefin resin powder, polyester resin powder, polyamide resin powder, polyimide resin powder, polyvinyl fluoride resin powder, etc. One type of these inorganic particles and organic particles may be used alone, or two or more types may be used in combination.

The particle diameter (D) (weight average particle diameter) of the aforementioned particles is not particularly limited, but is, for example, in the range of 2 to 10 μm. By setting the weight average particle diameter of the particles to the above range, for example, an anti-glare film with better anti-glare properties and suppressed reflection can be produced. From the viewpoint of suppressing oblique reflection, the weight average particle diameter of the aforementioned particles should not be too small. From the viewpoint of suppressing reflection from the front direction, the weight average particle diameter of the aforementioned particles should not be too large. The weight average particle diameter of the aforementioned particles may be, for example, 2.2 μm or more, 2.3 μm or more, 2.5 μm or more, or 3.0 μm or more, and may be 9.0 μm or less, 8.0 μm or less, 7.0 μm or less, or 6.0 μm or less. The weight average particle diameter of the particles may be, for example, 2.2 μm or more and 9.0 μm or less, 2.2 μm or more and 8.0 μm or less, 2.2 μm or more and 7.0 μm or less, 2.2 μm or more and 6.0 μm or less, 2.3 μm or more and 9.0 μm or less. 2.3 μm or more and 8.0 μm or less, 2.3 μm or more and 7.0 μm or less, 2.3 μm or more and 6.0 μm or less, 2.5 μm or more and 9.0 μm or less, 2.5 μm or more and 8.0 μm or less, 2.5 μm or more and 7.0 μm or less, 2.5 μm or more and 6.0 μm or less, 3.0 μm or more and 9.0 μm or less, 3.0 μm or more and 8.0 μm or less, 3.0 μm or more and 7.0 μm or less, or 3.0 μm or more and 6.0 μm or less. In addition, the weight average particle diameter of the aforementioned particles can be measured, for example, by the Coulter counting method. For example, a particle size distribution measuring device using the pore resistance method (trade name: Coulter Multisizer, manufactured by Beckman Coulter, Inc.) is used to measure the resistance of the electrolyte corresponding to the particle volume when the particles pass through the pores, thereby measuring The weight average particle diameter is calculated from the number and volume of the aforementioned particles.

The shape of the aforementioned particles is not particularly limited. For example, they may be roughly spherical in the form of beads, or may be irregular in shape such as powder. However, they are preferably generally spherical, and more preferably generally spherical particles with an aspect ratio of 1.5 or less. Most preferably are spherical particles.

The ratio of the particles in the anti-glare layer (B) may be, for example, 0.1 parts by weight or more, 0.2 parts by weight or more, 0.3 parts by weight or more, or 0.5 parts by weight or more, and may be 10 parts by weight or less based on 100 parts by weight of the resin. , 8 parts by weight or less, 7 parts by weight or less, or 6 parts by weight or less. The ratio of the particles may be, for example, 0.1 to 10 parts by weight, 0.1 to 8 parts by weight, 0.1 to 7 parts by weight, or 0.1 to 7 parts by weight based on 100 parts by weight of the resin. 6 parts by weight or less, 0.2 parts by weight or more and 10 parts by weight or less, 0.2 parts by weight or more and 8 parts by weight or less, 0.2 parts by weight or more and 7 parts by weight or less, 0.2 parts by weight or more and 6 parts by weight or less, 0.3 parts by weight or more and 10 parts by weight or less, 0.3 parts by weight or more and 8 parts by weight or less, 0.3 parts by weight or more and 7 parts by weight or less, 0.3 parts by weight or more and 6 parts by weight or less, 0.5 parts by weight or more and 10 parts by weight or less, 0.5 parts by weight or more and 8 parts by weight or less, 0.5 parts by weight or more and 7 parts by weight or less, or 0.5 parts by weight or more and 6 parts by weight or less. By setting the ratio of the particles to the above range, for example, the aggregation portion can be suitably formed, and for example, an anti-glare film with better anti-glare properties and suppressed reflection can be produced.

In the anti-glare layer (B), the filler may be particles or a thixotropic agent. The thixotropy-imparting agent may be contained alone, or the thixotropy-imparting agent may be contained in addition to the particles. By including the thixotropy-imparting agent, the aggregation state of the particles can be easily controlled. Examples of the thixotropy-imparting agent include organoclay, oxidized polyolefin, modified urea, and the like.

The aforementioned organoclay is preferably a layered clay that has been organically processed in order to improve the affinity with the aforementioned resin. The aforementioned organoclay can be prepared at home or commercially available products can be used. Examples of the aforementioned commercially available products include LOOSENTIGHT SAN, LOOSENTIGHT STN, LOOSENTIGHT SEN, LOOSENTIGHT SPN, SOMASIF ME-100, SOMASIF MAE, SOMASIF MTE, SOMASIF MEE, and SOMASIF MPE (trade names, all Co-op Chemical Co., Ltd. Made); ESBEN, ESBEN C, ESBEN E, ESBEN W, ESBEN P, ESBEN WX, ESBEN N-400, ESBEN NX, ESBEN NX80, ESBEN NO12S, ESBEN NEZ, ESBEN NO12, ESBEN NE, ESBEN NZ, ESBEN NZ70, ORGANITE , ORGANITE D, ORGANITE T (trade names, all manufactured by HOJUN Co., Ltd.); KUNIPIA F, KUNIPIA G, KUNIPIA G4 (trade names, all manufactured by KUNIMINE INDUSTRIES CO., LTD.); TIXOGEL VZ, CLAYTONE HT , CLAYTONE 40 (trade name, both manufactured by Rockwood Additives Ltd), etc.

The aforementioned oxidized polyolefin can be prepared at home or a commercially available product can be used. Examples of the commercially available products include DISPARLON 4200-20 (trade name, manufactured by Kusumoto Chemical Co., Ltd.), DISPARLON SA300 (trade name, manufactured by Kyeisha Chemical Co., Ltd.), and the like.

The reaction product of the aforementioned modified urea isocyanate monomer or its adduct and an organic amine. The aforementioned modified urea can be prepared at home or commercially available products can be used. Examples of the commercially available product include BYK410 (manufactured by BYK-CHEMIE Co., Ltd.).

The aforementioned thixotropy-imparting agent may be used alone or in combination of two or more types.

The ratio of the thixotropy-imparting agent in the anti-glare layer (B) is preferably in the range of 0.2 to 5 parts by weight, and more preferably in the range of 0.4 to 4 parts by weight relative to 100 parts by weight of the resin.

The maximum thickness (d’) of the aforementioned anti-glare layer (B) is not particularly limited, but should be in the range of 3~12 μm. By setting the maximum thickness (d') of the anti-glare layer (B) to the aforementioned range, for example, the anti-glare film can be prevented from curling, thereby avoiding productivity-lowering problems such as poor conveyability. In addition, when the thickness (d) falls within the above range, the weight average particle diameter (D) of the particles is preferably in the range of 2 to 10 μm as mentioned above. By using the above combination of the maximum thickness (d') of the anti-glare layer (B) and the weight average particle diameter (D) of the particles, an anti-glare film with excellent anti-glare properties can be produced. The maximum thickness (d’) of the aforementioned anti-glare layer (B) is more preferably in the range of 3~8 μm.

The ratio D/d of the thickness (d′) of the anti-glare layer (B) to the weight average particle diameter (D) of the particles may be, for example, 1 or less, 0.9 or less, 0.8 or less, 0.7 or less, or 0.6 or less, and may be Above 0.1, above 0.2, above 0.3 or above 0.4. The aforementioned D/d may be, for example, 0.1 or more and 1 or less, 0.2 or more and 1 or less, 0.3 or more and 1 or less, 0.4 or more and 1 or less, 0.1 or more and 0.9 or less, 0.2 or more and 0.9 or less, 0.3 or more and 0.9 or less, 0.4 Above and below 0.9, above 0.1 and below 0.8, above 0.2 and below 0.8, above 0.3 and below 0.8, above 0.4 and below 0.8, above 0.1 and below 0.7, above 0.2 and below 0.7, above 0.3 and below 0.7, above 0.4 and 0.7 or less, 0.1 or more and 0.6 or less, 0.2 or more and 0.6 or less, 0.3 or more and 0.6 or less, or 0.4 or more and 0.6 or less. By having such a relationship, an anti-glare film with better anti-glare properties and suppressed reflection can be produced.

In the anti-glare film of the present invention, for example, the anti-glare layer (B) has an agglomerated portion, and the agglomerated portion forms a convex portion on the surface of the anti-glare layer (B) by aggregation of the filler, thereby forming the convex portion. In the agglomerated part of the shape part, the filler may exist in a state where a plurality of fillers are aggregated in one direction in the surface direction of the anti-glare layer (B). This can prevent reflections of fluorescent lamps, for example. However, the anti-glare film of the present invention is not limited to this.

Moreover, the anti-glare film of the present invention may also have an intermediate layer between the above-mentioned translucent base material (A) and the above-mentioned anti-glare layer (B), for example. ) and the resin derived from the aforementioned anti-glare layer (B). By controlling the thickness of the intermediate layer, the surface shape of the anti-glare layer (B) can be controlled. For example, when the thickness of the intermediate layer is increased, the Rz and θa tend to become larger, and when the thickness of the intermediate layer is reduced, the Rz and θa tend to become smaller.

In the present invention, the mechanism for forming the aforementioned intermediate layer (also referred to as a permeable layer or a compatible layer) is not particularly limited. For example, it is formed in the aforementioned drying step in the inventor's method for producing an anti-glare film. Specifically, for example, in the aforementioned drying step, the coating liquid for forming the anti-glare layer (B) penetrates into the aforementioned translucent base material (A) to form a resin containing the resin derived from the aforementioned translucent base material (A). and the aforementioned intermediate layer made of resin derived from the aforementioned anti-glare layer (B). The resin contained in the intermediate layer is not particularly limited. For example, the resin contained in the translucent base material (A) and the resin contained in the anti-glare layer (B) may be simply mixed (miscible). Furthermore, among the resins contained in the intermediate layer, at least one of the resin contained in the translucent base material (A) and the resin contained in the anti-glare layer (B) may be chemically changed by heating, light irradiation, etc. .

The thickness ratio R of the intermediate layer defined by the following mathematical formula (5) is not particularly limited, and is, for example, 0.10 to 0.80, for example, 0.15 or more, 0.20 or more, 0.25 or more, 0.30 or more, 0.40 or more, or 0.45 or more, and for example It can be 0.75 or less, 0.70 or less, 0.65 or less, 0.60 or less, 0.50 or less, 0.40 or less, 0.45 or less or 0.30 or less. The aforementioned intermediate layer can be confirmed, for example, by observing the cross section of the anti-glare hard-coat film with a transmission electron microscope (TEM), and the thickness can be measured. R=[D _C /(D _C + D _B )] (5) In the aforementioned mathematical formula (5), D _B represents the thickness [μm] of the aforementioned anti-glare layer (B), and D _C represents the thickness of the aforementioned intermediate layer. [μm].

In the anti-glare film of the present invention, for example, as mentioned above, the anti-glare layer (B) has an agglomerated portion, and the agglomerated portion forms a convex portion on the surface of the anti-glare layer (B) by aggregation of the filler, thereby causing In the aggregated portion forming the convex portion, the filler may exist in a state where a plurality of fillers are aggregated in one direction in the surface direction of the anti-glare layer (B). This allows the convex portion to have an anisotropic and gentle shape. The anti-glare film can prevent reflection of fluorescent lamps and the like by having the convex portion having the above-mentioned shape. However, the anti-glare film of the present invention is not limited to this.

The surface shape of the anti-glare layer (B) can be arbitrarily designed by controlling the aggregation state of the filler contained in the material for forming the anti-glare layer. The aggregation state of the filler can be controlled, for example, by the material of the filler (such as the chemical modification state of the particle surface, affinity for solvents or resins, etc.), the type and combination of resin (binder) or solvent, etc. Furthermore, the aggregation state of the particles can be precisely controlled by the thixotropy-imparting agent. As a result, in the present invention, the surface shape of the anti-glare film can be controlled (adjusted) in a wide range. For example, the aggregation state of the filler can be made as described above, and the convex portion can be made into a gentle shape. Furthermore, the weight portion of the particles in the anti-glare layer forming material relative to 100 parts by weight of the resin can also be adjusted as described above, thereby controlling (adjusting) the surface shape of the anti-glare film in a wider range.

In addition, the anti-glare film of the present invention may be one in which the convex portion has a gentle shape to prevent the occurrence of protrusions on the surface of the anti-glare layer (B) that cause appearance defects, but is not limited thereto. Furthermore, the anti-glare film of the present invention may, for example, have some of the aforementioned particles at positions directly or indirectly overlapping with the anti-glare layer (B) in the thickness direction.

The aforementioned other layers are not particularly limited. For example, as mentioned above, they may be a low refractive index layer, a low reflection layer, a conductive layer, an antifouling layer, a high hardness layer, a high refractive index layer, a UV absorbing layer, etc. In addition, the aforementioned other layers may be one layer or a plurality of layers. When they are a plurality of layers, they may be one type or a plurality of types. For example, the aforementioned other layers may be optical films whose thickness and refractive index are strictly controlled, or may be laminated with two or more layers of the aforementioned optical films. Hereinafter, the case where the other layer is the low-reflective layer (C) will be described.

For example, when an anti-glare film is attached to an image display device, one of the main factors that may reduce image visibility may be light reflection at the interface between air and the anti-glare layer (B). The surface reflection can be reduced by the aforementioned low-reflective layer (C). In addition, the anti-glare layer (B) and the low-reflective layer (C) may be formed on only one side of the translucent base material (A) or may be formed on both sides. In addition, the anti-glare layer (B) and the low-reflection layer (C) may each have a multilayer structure in which two or more layers are laminated.

In the present invention, the low-reflective layer (C) may be an optical film whose thickness and refractive index are strictly controlled, or may be a layer in which two or more layers of the aforementioned optical film are laminated. The aforementioned low-reflective layer (C) can utilize the interference effect of light to cause the opposite phases of incident light and reflected light to cancel each other out, thereby exhibiting anti-reflective function. The wavelength range of visible light that can exhibit anti-reflection function is, for example, 380~780nm, and the wavelength range with particularly high optical visual efficiency is the range of 450~650nm. It can also be designed in such a way that the reflectivity of its central wavelength, which is 550nm, is minimized. The aforementioned low-reflective layer (C).

Furthermore, for example, in order to prevent adhesion of contaminants and improve the ease of removal of adhering contaminants, a fluorine-containing silane compound or a fluorine-containing organic compound may be laminated on the low-reflection layer (C). Anti-pollution layer formed.

[2. Manufacturing method of anti-glare film] The manufacturing method of the anti-glare film of the present invention is not particularly limited and can be manufactured by any method. However, it is preferably manufactured by the aforementioned manufacturing method of the anti-glare film of the present invention.

The anti-glare film can be produced in the following manner, for example.

First, the anti-glare layer (B) is formed on the translucent base material (A) in a manner that satisfies the aforementioned mathematical formulas (1) and (2) (anti-glare layer (B) forming step). Thereby, a laminated body of the said translucent base material (A) and the said anti-glare layer (B) is manufactured. The aforementioned anti-glare layer (B) forming step is as described above, including: a coating step, which is to apply a coating liquid on the aforementioned light-transmissive base material (A); and a coating film forming step, which is to apply the previously applied coating. The application liquid dries to form a coating film. Furthermore, for example, as mentioned above, the step of forming the anti-glare layer (B) may further include a hardening step of hardening the coating film. The aforementioned hardening may be performed, for example, after the aforementioned drying, but is not limited thereto. The aforementioned hardening can be performed, for example, by heating, light irradiation, or the like. The light is not particularly limited, and may be ultraviolet light, for example. The light source for the aforementioned light irradiation is not particularly limited, and may be a high-pressure mercury lamp, for example.

The coating liquid contains resin and solvent as mentioned above. The coating liquid may be, for example, an anti-glare layer forming material (coating liquid) containing the resin, the particles, the thixotropic agent, and the solvent.

The aforementioned coating liquid should exhibit thixotropy, and the Ti value specified by the following formula should be in the range of 1.3 to 3.5, more preferably in the range of 1.4 to 3.2, and even more preferably in the range of 1.5 to 3. Ti value=β1/β2 In the above formula, β1 is the viscosity measured using RheoStress RS6000 manufactured by HAAKE Company under the condition of shear rate 20 (1/s), and β2 is the viscosity measured using RheoStress RS6000 manufactured by HAAKE Company under the condition of shear rate 200 (1/s). Determination of viscosity.

As long as the Ti value is 1.3 or above, it is less likely to cause appearance defects or deterioration of anti-glare and whitening properties. In addition, as long as the Ti value is 3.5 or less, problems such as the particles not agglomerating and becoming dispersed are less likely to occur.

In addition, the coating liquid may or may not contain a thixotropy imparting agent, but it is preferable to include a thixotropy imparting agent since it can easily develop thixotropy. Furthermore, as mentioned above, when the coating liquid contains the thixotropy imparting agent, the effect of preventing the sedimentation of the particles (thixotropy effect) can be obtained. In addition, the surface shape of the anti-glare film can be freely controlled in a wider range by the shear aggregation of the thixotropy-imparting agent itself. For example, if the coating liquid does not contain particles but contains a thixotropy imparting agent, the anti-glare film of the present invention can be produced in which the θa and Rz are small and the unevenness of the outermost surface is gentle as described above. Furthermore, when the coating liquid contains a thixotropy imparting agent and particles with a small particle size, the anti-glare film of the present invention can be produced in which the θa and Rz are small and the unevenness of the outermost surface is gentle.

The solvent is not particularly limited, and various solvents can be used. One type may be used alone or two or more types may be used in combination. Depending on the composition of the resin, the type and content of the particles and the thixotropy-imparting agent, there are optimal solvent types and solvent ratios to obtain the anti-glare film of the present invention. The solvent is not particularly limited, and examples thereof include alcohols such as methanol, ethanol, isopropyl alcohol, butanol, and 2-methoxyethanol; and ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclopentanone. Classes; esters such as methyl acetate, ethyl acetate, butyl acetate; ethers such as diisopropyl ether, propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellulosine, etc. Cellulose; aliphatic hydrocarbons such as hexane, heptane, and octane; aromatic hydrocarbons such as benzene, toluene, and xylene, etc. Furthermore, for example, the aforementioned solvent may contain a hydrocarbon solvent and a ketone solvent. The hydrocarbon solvent may be, for example, aromatic hydrocarbons. The aromatic hydrocarbon may be, for example, at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene and benzene. The aforementioned ketone solvent may be selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone, for example. At least one of them. The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent in a mass ratio of 90:10 to 10:90. The mass ratio of the aforementioned hydrocarbon solvent to the aforementioned ketone solvent may be, for example, 80:20~20:80, 70:30~30:70, or 40:60~60:40, etc. At this time, for example, the aforementioned hydrocarbon solvent is toluene, and the aforementioned ketone solvent may be methyl ethyl ketone.

For example, when an acrylic film is used as the translucent base material (A) to form an intermediate layer (permeable layer), one that is a good solvent for the acrylic film (acrylic resin) can be suitably used. The solvent may be, for example, a solvent containing a hydrocarbon solvent and a ketone solvent as described above. The hydrocarbon solvent may be, for example, aromatic hydrocarbons. The aromatic hydrocarbon may be, for example, at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene and benzene. The aforementioned ketone solvent may be, for example, selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone and acetophenone. At least one of them. The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent in a mass ratio of 90:10 to 10:90. The mass ratio of the aforementioned hydrocarbon solvent to the aforementioned ketone solvent may be, for example, 80:20~20:80, 70:30~30:70, or 40:60~60:40, etc. At this time, for example, the aforementioned hydrocarbon solvent is toluene, and the aforementioned ketone solvent may be methyl ethyl ketone.

For example, when triacetyl cellulose (TAC) is used as the translucent base material (A) to form the intermediate layer (penetration layer), one that is a good solvent for TAC can be suitably used. Examples of the solvent include ethyl acetate, methyl ethyl ketone, cyclopentanone, and the like.

In addition, by appropriately selecting the solvent, when a thixotropy imparting agent is contained, the thixotropy to the anti-glare layer forming material (coating liquid) can be favorably exhibited. For example, when organic clay is used, toluene and xylene can be used alone or in combination. For example, when oxidized polyolefin is used, methyl ethyl ketone, ethyl acetate, and propylene glycol monomethyl ether can be used alone or in combination. When using modified urea, it can be suitably used alone or in combination with butyl acetate and methyl isobutyl ketone.

Various leveling agents can be added to the anti-glare layer forming material. As the leveling agent, for example, a fluorine-based or polysilicone-based leveling agent can be used in order to prevent uneven coating (uniformize the coating surface). In the present invention, when antifouling properties are required on the surface of the anti-glare layer (B), or when it is necessary to form a low-reflective layer (low refractive index layer) or a layer containing an interlayer filler on the anti-glare layer (B) as described later. Depending on the situation, choose an appropriate leveling agent. In the present invention, for example, the coating liquid can exhibit thixotropy by containing the aforementioned thixotropy-imparting agent, so that uneven coating is less likely to occur. In this case, there is an advantage that, for example, the options of the aforementioned leveling agent can be expanded.

The blending amount of the leveling agent is, for example, 5 parts by weight or less relative to 100 parts by weight of the resin, preferably in the range of 0.01 to 5 parts by weight.

Pigments, fillers, dispersants, plasticizers, ultraviolet absorbers, surfactants, antifouling agents, antioxidants, etc. can also be added to the aforementioned anti-glare layer-forming materials as needed within the scope that does not impair the performance. One type of these additives may be used alone, or two or more types may be used in combination.

For the anti-glare layer forming material, a conventionally known photopolymerization initiator described in Japanese Patent Application Laid-Open No. 2008-88309 can also be used.

The coating liquid can be applied to the translucent base material (A) to form a coating film using, for example, a spray coating method, a die coating method, a spin coating method, a spray coating method, a gravure coating method, or a roller coating method. Coating methods such as coating method and rod coating method.

Next, the coating film is dried and hardened as described above to form an anti-glare layer (B). The aforementioned drying may be, for example, natural drying, air drying by blowing air, heating drying, or a combination of these methods.

The drying temperature of the coating liquid for forming the anti-glare layer (B) may be, for example, in the range of 30 to 200°C. The aforementioned drying temperature may be, for example, 40°C or above, 50°C or above, 60°C or above, 70°C or above, 80°C or above, 90°C or above, or 100°C or above, and may be 190°C or below, 180°C or below, 170°C or below, 160°C or above. ℃ below, 150 ℃ below, 140 ℃ below, 135 ℃ below, 130 ℃ below, 120 ℃ below or 110 ℃ below. The drying time is not particularly limited, and may be, for example, 30 seconds or more, 40 seconds or more, 50 seconds or more, or 60 seconds or more, and may be 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less.

The method of curing the aforementioned coating film is not particularly limited, but ultraviolet curing is preferred. The irradiation dose of the energy ray source is preferably 50~500mJ/cm ² based on the cumulative exposure dose at the ultraviolet wavelength of 365nm. As long as the irradiation dose is 50 mJ/cm ² or more, hardening is likely to proceed sufficiently, and the hardness of the formed anti-glare layer (B) is likely to be high. In addition, as long as it is 500 mJ/cm ² or less, the formed anti-glare layer (B) can be prevented from being colored.

According to the above procedure, a laminate of the above-mentioned translucent base material (A) and the above-mentioned anti-glare layer (B) can be produced. This laminated body can be directly produced into the anti-glare film of the present invention, or, for example, the aforementioned other layer can be formed on the aforementioned anti-glare layer (B) to produce the anti-glare film of the present invention. The formation method of the aforementioned other layers is not particularly limited. For example, it can be the same as or follow the general formation method of low refractive index layer, low reflection layer, etc. Hereinafter, the step of forming the low-reflective layer (C) (low-reflective layer forming step) when the other layer is the low-reflective layer (C) will be described.

First, a low-reflection layer-forming coating liquid for forming the low-reflection layer (C) is prepared. The coating liquid for forming a low-reflective layer may contain, for example, a resin, an additive containing a fluorine element, hollow particles, solid particles, a diluting solvent, etc., and may be produced by mixing these.

Examples of the resin include thermosetting resins and free radiation-curing resins curable by ultraviolet rays or light. Commercially available thermosetting resin, ultraviolet curing resin, etc. can also be used as the aforementioned resin.

As the thermosetting resin or ultraviolet curing resin, for example, a curing compound having at least one of an acrylate group and a methacrylate group that can be cured by heat, light (ultraviolet, etc.) or electron rays can be used. Examples include polysilicone resin, polyester resin, polyether resin, epoxy resin, urethane resin, alkyd resin, spiroacetal resin, polybutadiene resin, polythiol polyene resin, and polyol. Oligomers or prepolymers of polyfunctional compounds such as acrylate or methacrylate. These may be used individually by 1 type or in combination of 2 or more types.

For example, a reactive diluent having at least one of an acrylate group and a methacrylate group can be used in the aforementioned resin. Examples of the reactive diluent include those described in Japanese Patent Application Laid-Open No. 2008-88309, and include, for example, monofunctional acrylates, monofunctional methacrylates, polyfunctional acrylates, polyfunctional methacrylates, and the like. The reactive diluent is preferably a trifunctional or higher acrylate or a trifunctional or higher methacrylate. This is because the low-reflection layer (C) can have excellent hardness. Examples of the reactive diluent include butanediol glyceryl ether diacrylate, isocyanuric acid acrylate, isocyanuric acid methacrylate, and the like. These may be used individually by 1 type or in combination of 2 or more types. The weight average molecular weight of the resin before curing may be, for example, 100 or more, 300 or more, 500 or more, 1,000 or more, or 2,000 or more, and may be 100,000 or less, 70,000 or less, 50,000 or less, 30,000 or less, or 10,000 or less. If the weight average molecular weight before hardening is high, the hardness will decrease, but it will tend to be less likely to break when it is bent. On the other hand, if the weight average molecular weight before hardening is low, the intermolecular cross-link density will increase and the hardness will tend to increase.

In order to harden the curable resin, for example, a hardener may be added. The hardening agent is not particularly limited, and for example, known polymerization initiators (such as thermal polymerization initiators, photopolymerization initiators, etc.) can be used appropriately. The amount of the hardening agent added is not particularly limited. It may be, for example, 0.5 parts by weight or more, 1.0 parts by weight or more, 1.5 parts by weight or more, or 2.0 parts by weight relative to 100 parts by weight of the resin in the low-reflective layer forming coating liquid. or more than 2.5 parts by weight, and may be less than 15 parts by weight, less than 13 parts by weight, less than 10 parts by weight, less than 7 parts by weight, or less than 5 parts by weight.

The aforementioned additives containing fluorine elements are not particularly limited. For example, they may be organic compounds or inorganic compounds containing fluorine in the molecule. The organic compound is not particularly limited, and examples thereof include fluorine-containing antifouling coating agents, fluorine-containing acrylic compounds, fluorine- and silicon-containing acrylic compounds, and the like. Specific examples of the organic compound include "KY-1203" and "KY-100", trade names manufactured by Shin-Etsu Chemical Industry Co., Ltd., "MEGAFACE", a trade name manufactured by DIC Co., Ltd., and the like. The aforementioned inorganic compounds are also not particularly limited. The amount of the fluorine-containing additive added is not particularly limited. For example, the weight of the fluorine element in the solid content may be, for example, 0.05% by weight or more, 0.1% by weight, relative to the total weight of the solid content in the low-reflective layer-forming coating liquid. More than 0.15% by weight, more than 0.20% by weight, or more than 0.25% by weight, and may be less than 20% by weight, less than 15% by weight, less than 10% by weight, less than 5% by weight, or less than 3% by weight. Moreover, for example, the weight of the additive containing the fluorine element may be, for example, 0.05% by weight or more, 0.1% by weight or more, 0.15% by weight or more, or 0.20% by weight relative to 100 parts by weight of the aforementioned resin in the aforementioned low-reflective layer forming coating liquid. % or more or 0.25% by weight or more, and may be 20% by weight or less, 15% by weight or less, 10% by weight or less, 5% by weight or less, or 3% by weight or less. From the viewpoint of the scratch resistance of the low-reflective layer (C), the amount of the fluorine-containing additive should not be too much or too little.

The aforementioned hollow particles are not particularly limited, and examples thereof include silicon oxide particles, acrylic particles, acrylic-styrene copolymer particles, and the like. Examples of the silicon oxide particles include "thruria 5320" and "thruria 4320", trade names manufactured by Nippon Chemical Industry Co., Ltd. The weight average particle diameter of the aforementioned hollow particles is not particularly limited, and may be, for example, 30 nm or more, 40 nm or more, 50 nm or more, 60 nm or more, or 70 nm or more, and may be 150 nm or less, 140 nm or less, 130 nm or less, 120 nm or less, or 110 nm or less. The shape of the aforementioned hollow particles is not particularly limited. For example, they may be roughly spherical in the shape of beads, or may be irregular in shape such as powder. However, they are preferably generally spherical, and more preferably generally spherical particles with an aspect ratio of 1.5 or less. Preferably spherical particles. By adding the hollow particles, for example, the low refractive index and good anti-reflective properties of the low-reflective layer (C) can be achieved. The amount of the hollow particles added is not particularly limited, but may be, for example, 30 parts by weight or more, 50 parts by weight or more, 70 parts by weight or more, or 90 parts by weight relative to 100 parts by weight of the resin in the low-reflective layer-forming coating liquid. or more than 100 parts by weight, and may be less than 300 parts by weight, less than 270 parts by weight, less than 250 parts by weight, less than 200 parts by weight, or less than 180 parts by weight. From the viewpoint of lowering the refractive index of the low-reflective layer (C), the added amount of the hollow particles is preferably not too small, and from the viewpoint of ensuring the mechanical properties of the low-reflective layer (C), the added amount of the hollow particles is preferably not excessive.

The aforementioned solid particles are not particularly limited, and may be, for example, silicon oxide particles, zirconium oxide particles, titanium-containing particles (eg, titanium oxide particles), and the like. Examples of the silicon oxide particles include product names "MEK-2140Z-AC", "MIBK-ST", and "IPA-ST" manufactured by Nissan Chemical Industry Co., Ltd. The weight average particle diameter of the solid particles is not particularly limited, and may be, for example, 5 nm or more, 10 nm or more, 15 nm or more, 20 nm or more, or 25 nm or more, and may be 3300 nm or less, 250 nm or less, 200 nm or less, 150 nm or less, or 100 nm or less. The shape of the aforementioned solid particles is not particularly limited. For example, they may be roughly spherical in the shape of beads, or may be irregular in shape such as powder. However, they are preferably generally spherical, and more preferably generally spherical particles with an aspect ratio of 1.5 or less. Preferably spherical particles. By adding the solid particles, for example, the fluorine-containing additive can easily exist locally on the surface of the coating liquid for forming the low-reflective layer, thereby improving the scratch resistance of the low-reflective layer (C). The low refractive index, good anti-reflective properties, etc. of the aforementioned low-reflective layer (C) can be achieved. The amount of the solid particles added is not particularly limited. It may be, for example, 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, or 20 parts by weight relative to 100 parts by weight of the resin in the coating liquid for forming a low-reflective layer. or more than 25 parts by weight, and may be less than 150 parts by weight, less than 120 parts by weight, less than 100 parts by weight, or less than 80 parts by weight. From the viewpoint of ensuring mechanical properties and adjusting the refractive index, the amount of the solid particles added should not be too small, and from the viewpoint of preventing cloudiness of the coating film caused by scattering, the amount of the solid particles added should not be too much.

The aforementioned dilution solvent is not particularly limited, and various solvents can be used. One type may be used alone or two or more types may be used in combination. Examples of the aforementioned dilution solvent include alcohols such as methanol, ethanol, isopropyl alcohol, butanol, TBA (tertiary butanol), and 2-methoxyethanol; acetone, methyl ethyl ketone, MIBK (methyl isobutyl alcohol), etc. ketones), cyclopentanone and other ketones; esters such as methyl acetate, ethyl acetate, butyl acetate, PMA (propylene glycol monomethyl ether acetate); ethers such as diisopropyl ether and propylene glycol monomethyl ether Categories; glycols such as ethylene glycol and propylene glycol; cellulosoids such as cellulosine and cellulose; aliphatic hydrocarbons such as hexane, heptane and octane; aromatic hydrocarbons such as benzene, toluene and xylene wait. For example, the polarity of the aforementioned diluting solvent can also be adjusted by mixing a plurality of solvents at any ratio.

The diluent solvent may be, for example, a mixed solvent containing MIBK (methyl isobutyl ketone) and PMA (propylene glycol monomethyl ether acetate). The mixing ratio at this time is not particularly limited. When the weight of MIBK is 100% by weight, the weight of PMA may be, for example, 20% by weight or more, 50% by weight or more, 100% by weight or more, 150% by weight or more, or 200% by weight. % or more, and may be 400 wt% or less, 350 wt% or less, 300 wt% or less, or 250 wt% or less.

The aforementioned diluting solvent may be, for example, a mixed solvent containing TBA (tertiary butanol) in addition to MIBK and PMA. The mixing ratio at this time is not particularly limited. When the weight of MIBK is 100% by weight, the weight of PMA may be, for example, 10% by weight or more, 30% by weight or more, 50% by weight or more, 80% by weight or more, or 100% by weight. % or more, and may be 200 wt% or less, 180 wt% or less, 150 wt% or less, 130 wt% or less, or 110 wt% or less. Furthermore, when the weight of MIBK is 100% by weight, the weight of TBA may be, for example, 10% by weight or more, 30% by weight or more, 50% by weight or more, 80% by weight or more, or 100% by weight or more, and may be 200% by weight. % or less, 180 wt% or less, 150 wt% or less, 130 wt% or less, or 110 wt% or less.

The amount of the diluting solvent added is not particularly limited. For example, the weight of the solid content may be, for example, 0.1% by weight or more, 0.3% by weight or more, or 0.5% by weight relative to the weight of the entire coating liquid for forming a low-reflective layer. or above, 1.0 wt% or more, or 1.5 wt% or more, and the weight of the solid content can be 20 wt% or less, 15 wt% or less, 10 wt% or less, 5 wt% or less, or 3 wt% or less. From the viewpoint of ensuring coating properties (wetting, leveling), the content of the solid content should not be too high, and from the viewpoint of preventing uneven drying, whitening, and other appearance defects caused by drying, the solid content should not be too high. The content rate should not be too low.

Next, the coating liquid for forming a low-reflective layer is applied on the anti-glare layer (B) (the coating step). The coating method is not particularly limited, and known coating methods such as spray coating, die coating, spin coating, spray coating, gravure coating, roll coating, and rod coating can be appropriately used. The coating amount of the low-reflection layer-forming coating liquid is not particularly limited, and the thickness of the low-reflection layer (C) formed can be, for example, 0.1 μm or more, 0.3 μm or more, 0.5 μm or more, or 1.0 μm. or 2.0 μm or more, and the thickness of the low-reflective layer (C) formed may be 50 μm or less, 40 μm or less, 30 μm or less, 20 μm or less, or 10 μm or less.

Next, the application liquid for forming a low-reflective layer is dried to form a coating film (the coating film forming step). The drying temperature is not particularly limited, and may be in the range of 30 to 200°C, for example. The aforementioned drying temperature may be, for example, 40°C or above, 50°C or above, 60°C or above, 70°C or above, 80°C or above, 90°C or above, or 100°C or above, and may be 190°C or below, 180°C or below, 170°C or below, 160°C or above. ℃ below, 150 ℃ below, 140 ℃ below, 135 ℃ below, 130 ℃ below, 120 ℃ below or 110 ℃ below. The drying time is not particularly limited, and may be, for example, 30 seconds or more, 40 seconds or more, 50 seconds or more, or 60 seconds or more, and may be 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less.

Furthermore, the coating film may be hardened (hardening step). The aforementioned hardening can be performed, for example, by heating, light irradiation, or the like. The light is not particularly limited, and may be ultraviolet light, for example. The light source for the aforementioned light irradiation is not particularly limited, and may be a high-pressure mercury lamp, for example. The irradiation dose of the aforementioned energy ray source for ultraviolet curing is preferably 50~500mJ/cm ² based on the cumulative exposure dose at the ultraviolet wavelength of 365nm. As long as the irradiation dose is 50 mJ/cm ² or more, sufficient hardening can easily occur, and the hardness of the formed low-reflective layer (C) can easily become high. In addition, as long as it is 500 mJ/cm ² or less, the formed low-reflective layer (C) can be prevented from being colored.

According to the above procedure, the anti-reflective film of the present invention can be produced with the anti-glare layer (B) and the low-reflective layer (C) sequentially laminated on at least one side of the translucent base material (A). In addition, as mentioned above, the anti-reflective film of the present invention may also include other layers other than the aforementioned translucent base material (A), the aforementioned anti-glare layer (B), and the aforementioned low-reflective layer (C).

In addition, in the manufacturing step of the anti-reflective film of the present invention, it is preferable to perform surface treatment on at least one of the above-mentioned translucent base material (A) and the above-mentioned anti-glare layer (B). As long as the surface of the above-mentioned translucent base material (A) is surface-treated, the adhesion with the above-mentioned anti-glare layer (B) or polarizer or polarizing plate can be further improved. In addition, as long as the surface of the anti-glare layer (B) is surface-treated, the adhesion with the low-reflective layer (C) can be further improved.

[3. Optical components and image display devices] The optical component of the present invention is not particularly limited, and may also be a polarizing plate, for example. The aforementioned polarizing plate is not particularly limited. For example, it may include the anti-glare film of the present invention and a polarizer, and may further include other components. Each component of the polarizing plate can be bonded together using an adhesive or an adhesive, for example.

The image display device of the present invention is not particularly limited and can be any image display device, such as a liquid crystal display device, an organic EL display device, etc.

The image display device of the present invention is, for example, an image display device having the anti-glare film of the present invention on the viewing side surface, and the aforementioned image display device may also have a black matrix pattern.

For example, the anti-glare film of the present invention can be bonded to an optical member for an LCD by using an adhesive or an adhesive agent on the light-transmitting base material (A) side. In addition, during this lamination, the surface of the aforementioned translucent base material (A) may also be subjected to various surface treatments as described above. As mentioned above, according to the manufacturing method of the anti-glare film of the present invention, the surface shape of the anti-glare film can be freely controlled in a wide range. Therefore, the optical properties that can be obtained by laminating the anti-glare film and other optical members using an adhesive, an adhesive, or the like cover a wide range corresponding to the surface shape of the anti-glare film.

Examples of the optical member include polarizers and polarizing plates. The composition of a polarizing plate generally consists of a transparent protective film on one side or both sides of the polarizing element. When it is desired to install transparent protective films on both sides of the polarizer, the transparent protective films on the front and back can be made of the same material or different materials. Polarizing plates are usually placed on both sides of the liquid crystal unit. Moreover, the polarizing plates are arranged so that the absorption axes of the two polarizing plates are substantially orthogonal to each other.

The composition of the polarizing plate on which the anti-glare film is laminated is not particularly limited. For example, the polarizing plate may have a transparent protective film, the polarizing element, and the transparent protective film laminated in this order on the anti-glare film. It may also be composed of The above-mentioned anti-glare film is composed of the above-mentioned polarizer and the above-mentioned transparent protective film laminated in this order.

The image display device of the present invention has the same structure as the conventional image display device except that the anti-glare film is arranged in a specific direction. For example, in the case of an LCD, it can be manufactured by appropriately assembling each component part such as a liquid crystal unit, optical components such as polarizers, and lighting systems (backlights, etc.) according to requirements, and then integrating them into drive circuits.

The image display device of the present invention can be used for any appropriate purpose. Its uses include computer monitors, notebook computers, copy machines and other OA equipment, mobile phones, clocks, digital cameras, portable information terminals (PDA), portable game consoles and other portable equipment, video cameras, televisions, microwave ovens, etc. Household electrical equipment, rear view monitors, monitors for car navigation systems, in-vehicle equipment such as car audio, display equipment such as information guide screens for commercial stores, security equipment such as monitoring screens, nursing monitors, and medical use Monitors and other medical care equipment. Example

Next, examples of the present invention will be described together with comparative examples. However, the present invention is not limited to the following examples and comparative examples.

In addition, in the following examples and comparative examples, the parts of substances are parts by mass (parts by weight) unless otherwise specified.

[Coating liquid 1: anti-glare layer forming material] As the resin contained in the anti-glare layer, 40 parts by weight of urethane acrylate prepolymer (manufactured by Shin-Nakamura Chemical Industry Co., Ltd., trade name "UA-53H-80BK", solid content 80%) and neopentyl erythritol were prepared. 60 parts by weight of polyfunctional acrylate (manufactured by Osaka Organic Chemical Industry Co., Ltd., trade name "Viscoat #300", solid content 100%) containing triacrylate as the main component. For every 100 parts by weight of the resin solid content of the above-mentioned resin, 1.2 parts by weight of synthetic bentonite (manufactured by Co-op Chemical Co., Ltd., trade name "LOOSENTIGHT SAN") as an organic clay as a thixotropy-imparting agent was mixed. 5 parts by weight of starter agent (manufactured by BASF, trade name "IRGACURE 907") and 0.15 parts by weight of leveling agent (manufactured by Kyeisha Chemical Co., Ltd., trade name "LE-303", solid content 40%). In addition, the aforementioned organoclay was diluted with toluene to a solid content of 6% by weight before use. This mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) to a solid content concentration of 40% by weight, and an anti-glare layer forming material (coating liquid) was prepared using an ultrasonic disperser. 1).

[Coating liquid 2: low-reflective layer forming material] As the resin contained in the low-reflective layer, 100 weight of polyfunctional acrylate (manufactured by Osaka Organic Chemical Industry Co., Ltd., trade name "Viscoat #300", solid content 100%) containing neopentyl erythritol triacrylate as the main component was prepared. share. For every 100 parts by weight of the resin solid content of the aforementioned resin, 30 parts by weight of organic silica sol (particle diameter 10~15 nm), 100 parts by weight of hollow silicon oxide particles (weight average particle diameter 75 nm), and photopolymerization initiator (BASF Company) were mixed. Manufactured under the trade names "IRGACURE 907" and "IRGACURE 2959"), a total of 10 parts by weight and 10 parts by weight of fluorine-based antifouling additives containing free radical reactive groups. This mixture was diluted with a methyl isobutyl ketone/propylene glycol monomethyl ether acetate mixed solvent (weight ratio 25/75) to a solid content concentration of 1.5% by weight, and then an anti-glare layer was prepared using an ultrasonic disperser. Material (coating fluid 2).

[Coating liquid 3: anti-glare layer forming material] The coating liquid 1 was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration became 42% by weight, and an anti-glare layer forming material (coating liquid 3) was prepared.

[Coating liquid 4: Anti-glare layer forming material] 0.5 parts by weight of inorganic particles (Sekisui Chemicals Co., Ltd., product name "Techpolymer SSX-103DXE", weight average particle size 3.0μm) were mixed with 100 parts by weight of the resin solid content in coating liquid 1 to obtain a mixture. The mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) to a solid content concentration of 42% to prepare an anti-glare layer forming material (coating liquid 4).

[Coating liquid 5: anti-glare layer forming material] The coating liquid 1 was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration became 38% by weight, and an anti-glare layer forming material (coating liquid 3) was prepared.

[Coating liquid 6: anti-glare layer forming material] The coating liquid 1 was mixed with 0.5 part by weight of inorganic particles (Sekisui Chemical Industry Co., Ltd., product name "Techpolymer SSX-103DXE") per 100 parts by weight of the resin solid content to obtain a mixture. This mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration became 40% by weight, and an anti-glare layer forming material (coating liquid 6) was prepared.

[Coating liquid 7: anti-glare layer forming material] The coating liquid 1 was mixed with 0.5 part by weight of inorganic particles (Sekisui Chemical Industry Co., Ltd., product name "Techpolymer SSX-103DXE") per 100 parts by weight of the resin solid content to obtain a mixture. This mixture was diluted with a toluene/methyl ethyl ketone (MEK) mixed solvent (weight ratio 70/30) so that the solid content concentration became 38% by weight, and an anti-glare layer forming material (coating liquid 6) was prepared.

[Example 1] An anti-glare film is produced according to the following procedure.

As the translucent base material (A), a transparent plastic film base material (acrylic film, manufactured by Toyo Steel Co., Ltd., trade name "HX-40UC", thickness: 40 μm, refractive index: 1.50) was prepared. The anti-glare layer forming material (coating liquid 1) is coated on one side of the transparent plastic film base material with a wire bar to form a coating film (coating step). Next, the coating film was dried by heating at 100° C. for 1 minute (drying step). Thereafter, a high-pressure mercury lamp was used to irradiate ultraviolet light with a cumulative light intensity of 300 mJ/cm ² to harden the aforementioned coating film to form an anti-glare layer (B) with a thickness of 6.5 μm. In addition, the anti-glare layer (B) in the anti-glare film of this embodiment is an anti-glare hard coat layer. The same applies to all the following Examples and Comparative Examples.

Then, the low-reflective layer forming material (coating liquid 2) is coated on the anti-glare layer (B) using a spin coater to form a coating film (coating step). Next, the coating film was dried by heating at 90° C. for 1 minute (drying step). Thereafter, a high-pressure mercury lamp was used to irradiate ultraviolet light with a cumulative light intensity of 300 mJ/cm ² to harden the aforementioned coating film to form a low-reflective layer (C) with a thickness of 100 nm, thereby obtaining the anti-glare film of this embodiment.

[Example 2] An anti-glare film was produced in the same manner as in Example 1 except that the coating liquid 3 was used as the anti-glare layer forming material instead of the coating liquid 1.

[Example 3] An anti-glare film was produced in the same manner as in Example 1 except that the coating liquid 4 was used as the anti-glare layer forming material instead of the coating liquid 1.

[Example 4] An anti-glare film was produced in the same manner as in Example 1 except that the coating liquid 5 was used as the anti-glare layer forming material instead of the coating liquid 1.

[Example 5] An anti-glare film was produced in the same manner as in Example 1 except that the thickness (film thickness) of the anti-glare layer (B) was 8.5 μm.

[Example 6] The anti-glare layer forming material was prepared in the same manner as in Example 1 except that the coating liquid 6 was used instead of the coating liquid 1 and the thickness (film thickness) of the anti-glare layer (B) was 5.0 μm. Anti-glare film.

[Example 7] An anti-glare film was produced in the same manner as in Example 1, except that the low-reflective layer (C) was not formed on the anti-glare layer (B).

[Comparative example 1] An anti-glare film was produced in the same manner as in Example 1 except that the coating liquid 6 was used as the anti-glare layer forming material instead of the coating liquid 1.

[Comparative example 2] The anti-glare layer forming material was prepared in the same manner as in Example 1 except that the coating liquid 6 was used instead of the coating liquid 1 and the thickness (film thickness) of the anti-glare layer (B) was 8.5 μm. Anti-glare film.

[Comparative example 3] An anti-glare film was produced in the same manner as in Example 1 except that the coating liquid 7 was used as the anti-glare layer forming material instead of the coating liquid 1.

[Comparative example 4] An anti-glare film was produced in the same manner as in Comparative Example 1, except that the low-reflective layer (C) was not formed on the anti-glare layer (B).

For the anti-glare films of Examples 1 to 7 and Comparative Examples 1 to 4 produced according to the above procedures, the outermost surface of the anti-glare layer (B) side (anti-glare layer (B) surface) was measured or calculated by the following method. Or the average inclination angle θa (°) of the unevenness of the low-reflective layer (C) surface), the ten-point average height Rz (μm), the arithmetic average surface roughness Ra (μm) and the average distance between unevenness Sm (mm).

[Measurement and calculation method of concave and convex shapes] According to JIS B0601 (1994 edition), the average unevenness distance Sm (mm), the ten-point average height Rz (μm), and the arithmetic mean surface roughness Ra (μm) of the anti-glare film are measured. Specifically, first, a glass plate (MICRO SLIDE GLASS, model S, manufactured by MATSUNAMI Co., Ltd., thickness 1.3 mm, 45×50 mm) is bonded to the light-transmitting base material (A) of the anti-glare film with an adhesive. The surface opposite to the glare layer (B) is used to prepare a sample. Next, a stylus-type surface roughness measuring instrument (high-precision fine shape measuring instrument manufactured by Kosaka Research Institute, trade name "SURFCORDER ET4000") having a measuring needle with a curvature radius R=2 μm at the tip (diamond) is used. , under the conditions of scanning speed 1mm/second, cut-off value 0.8mm, and measurement length 12mm, measure the outermost surface (anti-glare layer (B) surface or low reflection) of the anti-glare layer (B) side of the aforementioned sample in a fixed direction. The uneven shape of layer (C) surface). Based on this measurement, the average distance Sm (mm) between concavities and convexities on the outermost surface, the ten-point average height Rz, and the arithmetic average surface roughness Ra were calculated. The average inclination angle θa (°) is calculated from the surface roughness curve obtained from the measured value (calculated value). In addition, the high-precision fine shape measuring device can automatically calculate each of the above-mentioned measurement values.

Furthermore, whether the anti-glare films of Examples 1 to 7 and Comparative Examples 1 to 4 suppressed the generation of white fog was determined (evaluated) by the following method.

[Method for determining white fog] (1) Use an adhesive to bond a black acrylic plate (manufactured by MITSUBISHI RAYON CO., LTD., thickness 2.0 mm) to the translucent base material (A) of the anti-glare film without forming an anti-glare layer (B) ) surface to produce a sample with the back reflection eliminated. (2) Irradiate the above-mentioned sample with a fluorescent lamp (three-wavelength light source) in an office environment where a monitor is generally used (about 1000Lx), and judge the white haze of the above-mentioned sample with the naked eye according to the following standards. Judgment criteria OK: The wavy color difference between black and white is not visible, or the color difference is so light that there is no problem in practical applications. NG: Visible black and white wavy color difference.

The uneven shapes and white haze determination results of the aforementioned outermost surfaces of the anti-glare films of Examples 1 to 7 and Comparative Examples 1 to 4 are summarized in Table 1 below.

[Table 1]

As shown in the aforementioned Table 1, the anti-glare films of Examples 1 to 7 that satisfy θa≦0.24 and Rz≦0.20 can suppress white fog. On the other hand, the anti-glare films of Comparative Examples 1 to 4, which did not satisfy both θa≦0.24 and Rz≦0.20, did not sufficiently suppress white fog. In addition, regarding the anti-glare properties, the anti-glare films of Examples 1 to 7 all successfully prevented the reflection of the outline image of the fluorescent lamp under the conditions of the aforementioned white fog determination method. From this, it can be seen that these films have no problems in practical applications. level.

Industrial applicability As described above, according to the present invention, an anti-glare film that suppresses the generation of white haze, a method for manufacturing the anti-glare film, an optical component, and an image display device can be provided. The use of the present invention is not particularly limited, and can be used in a wide range of applications, for example, it can be applied to any image display device.

This application claims priority based on Japanese application No. 2018-213945 filed on November 14, 2018, and the entire disclosure is incorporated herein.

10: Anti-glare film 11: Translucent base material (A) 12: Anti-glare layer (B) 12a: Resin layer 12b:Particles 12c: Thixotropy imparting agent 13: Low reflective layer (C) (other layers)

FIG. 1 is a cross-sectional view showing an example of the structure of the anti-glare film of the present invention. FIG. 2 is a cross-sectional view showing another example of the structure of the anti-glare film of the present invention. FIG. 3 is a cross-sectional view showing yet another example of the structure of the anti-glare film of the present invention. Figure 4 is a cross-sectional view showing yet another example of the structure of the anti-glare film of the present invention.

10: Anti-glare film

11: Translucent base material (A)

12: Anti-glare layer (B)

12a: Resin layer

12b:Particles

12c: Thixotropy imparting agent

13: Low reflective layer (C) (other layers)

Claims (14)

An anti-glare film having an anti-glare layer (B) laminated on a translucent base material (A), characterized in that the anti-glare layer (B) contains particles, and the particle size of the particles (D) (Weight average particle diameter) is in the range of 2 to 10 μm, and the anti-glare film has unevenness formed on the outermost surface of the anti-glare layer (B) side, and the unevenness satisfies the following mathematical formulas (1) and ( 2): 0.15≦θa≦0.24 (1) 0.17≦Rz≦0.20 (2) In the aforementioned mathematical formula (1), θa represents the average inclination angle [°] of the aforementioned concavity and convexity. In the aforementioned mathematical formula (2), Rz represents the aforementioned concavity and convexity. The ten-point average height [μm]. For example, the anti-glare film of claim 1 further satisfies the following mathematical formula (3): Ra≦0.050 (3) In the aforementioned mathematical formula (3), Ra represents the arithmetic mean surface roughness [μm] of the aforementioned unevenness. The anti-glare film of claim 1, wherein another layer is laminated on the surface of the anti-glare layer (B) opposite to the translucent base material (A). An anti-glare film in which an anti-glare layer (B) and other layers are sequentially laminated on a translucent base material (A), characterized in that: the anti-glare layer (B) contains particles, and the particles are The particle diameter (D) (weight average particle diameter) is in the range of 2 to 10 μm, and unevenness is formed on the outermost surface of the other layers, and the unevenness satisfies the following mathematical formulas (1) and (2): 0.15≦θa≦ 0.24 (1) 0.17≦Rz≦0.20 (2) In the aforementioned mathematical formula (1), θa represents the average inclination angle [°] of the aforementioned concavities and convexities, and in the aforementioned mathematical formula (2), Rz represents the ten-point average height [μm] of the aforementioned concavities and convexities. The anti-glare film of claim 3 or 4, wherein the aforementioned other layers are low-reflective layers (C). The anti-glare film according to any one of claims 1 to 4, wherein the anti-glare layer (B) includes a binder resin and a cohesive filler. The anti-glare film of claim 6, wherein the agglomerative filler is organoclay. A method for manufacturing an anti-glare film, which is the method for manufacturing an anti-glare film according to any one of claims 1 to 7. The method is characterized by comprising the following steps: an anti-glare layer (B) forming step, which is The above-mentioned anti-glare layer (B) is formed on the above-mentioned translucent base material (A); and the step of forming unevenness is to satisfy the above-mentioned mathematical formula ( The aforementioned unevenness is formed in the manner of 1) and (2); the aforementioned anti-glare layer (B) forming step includes: a coating step of applying a coating liquid on the aforementioned translucent base material (A); and a coating film forming step, The coating film is formed by drying the coating liquid before application; and the coating liquid contains a resin, a solvent and the particles. The manufacturing method of claim 8, wherein the step of forming the anti-glare layer (B) further includes a hardening step of hardening the coating film. The manufacturing method of claim 8, wherein the aforementioned solvent includes toluene and methyl ethyl ketone. The manufacturing method according to any one of claims 8 to 10, wherein the anti-glare film is the anti-glare film according to any one of claims 3 to 5; and the unevenness forming step is included in the anti-glare layer (B ) and other layer forming steps for forming the aforementioned other layers. An optical member including the anti-glare film according to any one of claims 1 to 7. The optical component of claim 12 is a polarizing plate. An image display device, including the anti-glare film according to any one of claims 1 to 7, or the optical member according to claim 12 or 13.

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