WO2012108209A1 - Procédé pour produire un film optique - Google Patents

Procédé pour produire un film optique Download PDF

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Publication number
WO2012108209A1
WO2012108209A1 PCT/JP2012/000893 JP2012000893W WO2012108209A1 WO 2012108209 A1 WO2012108209 A1 WO 2012108209A1 JP 2012000893 W JP2012000893 W JP 2012000893W WO 2012108209 A1 WO2012108209 A1 WO 2012108209A1
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WIPO (PCT)
Prior art keywords
film
layer
refractive index
embossing
optical film
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PCT/JP2012/000893
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English (en)
Japanese (ja)
Inventor
寛行 大西
Original Assignee
コニカミノルタオプト株式会社
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Priority to JP2012556802A priority Critical patent/JPWO2012108209A1/ja
Publication of WO2012108209A1 publication Critical patent/WO2012108209A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0074—Production of other optical elements not provided for in B29D11/00009- B29D11/0073
    • B29D11/00788—Producing optical films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B3/00—Presses characterised by the use of rotary pressing members, e.g. rollers, rings, discs
    • B30B3/005—Roll constructions
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11—Anti-reflection coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B29C2059/023—Microembossing

Definitions

  • the present invention relates to a method for producing an optical film.
  • an optical film for a display device As such an optical film for a display device, a wide film having a size of 1000 mm or more, and further 2000 mm or more has recently been required due to a large screen. In addition, a thin base film having a thickness of about 40 ⁇ m has been used for mobile phones and notebook computers. Therefore, a resin film such as cellulose ester is used as the base film, and a hard coat layer, an antireflection layer, an antifouling layer or an antiglare layer is formed thereon as an optical functional layer.
  • a resin film such as cellulose ester is used as the base film, and a hard coat layer, an antireflection layer, an antifouling layer or an antiglare layer is formed thereon as an optical functional layer.
  • the base film becomes wider for widening as described above, or when the thickness of the base film is reduced for thinning, the optical film after forming the optical functional layer In the stage of winding up, non-uniform portions of the roll tightening are likely to occur.
  • This non-uniform winding of the roll also facilitates adhesion between the film surfaces (hereinafter referred to as blocking).
  • a film fed out from a roll in which blocking occurs causes wrinkles, scratches, etc., and cannot be applied to a display device, resulting in a decrease in yield.
  • Patent Document 1 an embossing roll having a tooth tip shape of 90 ° to 130 ° is used to press against the surface of the film end, and the film thickness at the film end is deformed to make the embossing process bulky. A way to do it has been proposed.
  • the occurrence of the fibrous foreign matter deteriorates the embossed surface and reduces the shape of the convex portion (hereinafter referred to as a rib) formed on the embossed surface.
  • the present invention has been made in view of the prior art, and the problem to be solved is that, in the step of embossing the base film, the end of the film does not stretch when the embossed stamp is pressed.
  • Another object of the present invention is to provide a method for producing an optical film that does not generate a black band in a roll shape.
  • the present inventors in a high-speed optical film manufacturing method having a film-forming speed of 80 m / min or more, include an embossing ring imprinting ring provided in an embossing device used for the manufacturing. Attention was paid to the study. As a result, it was found that by polishing the surface of the engraved ring so as to be in a specific range, the end portion of the optical film does not occur, and no black band occurs when it is formed into a roll. It came to complete.
  • the method for producing an optical film according to the present invention uses an embossing device having an embossing roll having an engraved ring and an embossing back roll, and presses the embossing roll against a long film serving as a substrate.
  • Optical film manufacturing method In the manufacturing method of the optical film according to the present embodiment, after the embossing roll is pressed against the long film serving as the base material using an embossing device provided with a marking ring and an embossing roll, An optical film produced by winding the film, characterized in that the film-forming speed is 80 m / min or more, and the surface roughness Ra of the side surface of the marking ring is 10 to 20 ⁇ m.
  • the surface roughness Ra of the side surface of the marking ring is set to 10 to 20 ⁇ m, so that the edge elongation occurs when the embossing ring pushes the base film. Hard to do. In addition, it is possible to prevent the occurrence of so-called blocking caused by sticking of beards or the like, and the occurrence of black bands.
  • the step of embossing in the present invention is to form an uneven portion on the surface of the base film by pressing an embossing roll having uneven portions on the surface of the long film as the base material, It is the process of making it bulkier than the film surface.
  • the surface layer of the embossing roll at the time of production is at least carbide, nitride, carbon nitride, diamond-like carbon (hereinafter referred to as DLC), titanium carbonitride (hereinafter referred to as “carbonic nitride”). , Referred to as TiCN).
  • coats an optical functional layer It is preferable to apply before and after the step. By doing in this way, an optical function layer can be apply
  • FIG. 1 (a) schematically shows a plan view of the optical film 1 of the present invention having an embossed portion.
  • the embossed portion 12 is a portion of a plurality of irregularities (convex portions 13 and concave portions 14) that are bulkier than the surface of the optical film side end portion, and is formed in the longitudinal direction of the optical film 1.
  • An optical functional layer may be applied to the surface of the optical film 1, and in this case, the embossed portion 12 is formed higher than the surface of the uppermost layer of the optical functional layer. Further, when the optical functional layer is not applied, an embossed portion higher than the surface of the optical film 1 is formed.
  • the shape of the unevenness is not particularly limited, and various patterns may be used, or a convex thick film portion may be formed.
  • FIG. 1 (b) shows a cross-sectional view in which a pair of irregularities (13, 14) among a plurality of irregularities of the formed embossed portion 12 is cut in the thickness direction of the optical film 1.
  • FIG. 2 is a cross-sectional view of the convex portion 13 of FIG. 1 cut along a plane (AA in FIG. 1) parallel to the surface of the optical film 1 and at half the height H of the convex portion 13. .
  • the width W of the convex shape at the cross section is preferably 3 to 100 ⁇ m, and more preferably 10 to 30 ⁇ m. If the average width is smaller than 3 ⁇ m, the strength is insufficient, and if it is larger than 100 ⁇ m, a flare failure due to end elongation occurs.
  • the average width W is determined by measuring the widths W1, W2, W3, and W4 of the central portion of each knitting of the cross-sectional shape of the convex portion 13 in FIG. If the cross-sectional shape is not a quadrangle as shown in FIG. 2, four points are measured at almost equal intervals, and the average value is calculated.
  • the cross-sectional area S in the range of 2500 to 10000 ⁇ m 2 , even if the winding speed is increased or the winding length is increased, the generation of a black band in a rolled state is suppressed. And an optical film with few wrinkles and scratches can be obtained.
  • the average height H ( ⁇ m) from the surface of the convex film is preferably 1.0 to 20 ⁇ m, and more preferably 3 to 10 ⁇ m. If the average height H is less than 1.0 ⁇ m, the film interlayer height is insufficient, and if it is greater than 20 ⁇ m, winding tightening tends to occur.
  • the ratio S / H between the cross-sectional area S ( ⁇ m 2 ) and the average height H ( ⁇ m) from the surface of the convex film is preferably 100 to 3000.
  • S / H The average height H from the film surface was determined by measuring the height of the convex portion from the film surface at 10 places at approximately equal intervals and 3 rows in width, and taking the average value of 30 points in total.
  • the ratio S / Y between the above-mentioned cross-sectional area S ⁇ m 2 and the widest width Y ⁇ m of the recess is preferably 10 to 300.
  • S / Y is a portion of the widest distance in the width of the recess for the cross-sectional view of FIG.
  • 10 to 300 pieces / cm 2 of a pair of irregularities are formed on the side end portion of the embossed film.
  • the pair of irregularities it is possible to further suppress the generation of black bands in a rolled state, and to obtain an optical film with fewer wrinkles and scratches.
  • a plurality of engraved rings are pressed against the surface of the side end portion of the film to form a plurality of concave and convex pairs.
  • the height of the convex portion formed by the film member pushed away by the marking ring is preferably set to a predetermined height depending on the pressure and processing temperature for pressing the marking ring.
  • the process of embossing is before and after the process of apply
  • an embossing roll 61 having a plurality of engraved rings 20 on a cylindrical flat surface 21 (also referred to as a flat portion), and the embossing roll 61 and the optical film 1 are disposed to face each other. It is the figure which showed typically the embossing process of embossing to the both ends of the optical film 1 with the embossing back roll 62.
  • FIG. 3A shows typically the embossing process of embossing to the both ends of the optical film 1 with the embossing back roll 62.
  • FIG. 3B is an enlarged view of a forming portion for forming irregularities on the optical film by the marking ring 20.
  • the marking ring 20 has a quadrangular pyramid shape in which the tip portion 20a has a flat surface.
  • the engraved ring 20 is pressed against the surface of the film 1 with a gap to form the convex portion 13.
  • a quadrangular pyramid having a flat surface on the upper surface (pressing surface) of the marking 61 is used as an example.
  • a triangular pyramid, a conical shape, or a cylindrical shape may be used. May be.
  • FIG. 4 is a schematic view showing the embossing process of FIG. 3B from the side.
  • a convex portion 13 having a width B and a height h is formed at the end in the width direction of the optical film 1.
  • the height h of the emboss refers to the height from the film surface to the convex portion formed by the emboss roll.
  • the heating method of the embossing roll 61 is not specifically limited, A heating fluid can be flowed inside a roll, a halogen heater can be used, or it can heat by dielectric heat_generation
  • the emboss height h needs to be a predetermined height to prevent blocking and black bands. Therefore, in order to obtain a predetermined emboss height h, the surface temperature of the embossing roll 61 and the pressing pressure of the embossing roll are adjusted. However, due to the friction between the embossing roll and the marking ring, a short whisker-like fibrous foreign matter may be generated on the unevenness of the embossed portion.
  • the size of the whisker-like fibrous foreign matter is about 1 to 100 ⁇ m in diameter and about 10 to 1000 ⁇ m in length, and when the width B is 2 cm, the number of generated is about 1 to 50 per embossed unevenness. appear.
  • the whiskers cause whisker-like fibrous foreign matter due to local expansion of the thermoplastic optical film 1.
  • the film forming speed is high, particularly when the film forming speed is 80 m / min or more, the whisker-like fibrous foreign matter makes the embossed height non-uniform, and a black band is generated when it is made into a roll shape or is detached from the embossed part. As a result, it is possible that the foreign matter adheres to the film.
  • the surface roughness Ra of the side surface of the marking ring is 10 to 20 ⁇ m, and preferably 13 to 17 ⁇ m. If Ra is less than 10 ⁇ m, end portion elongation tends to occur, and if it is larger than 20 ⁇ m, whiskers are likely to occur.
  • the surface roughness Ra of the upper surface of the marking ring is 10 to 20 ⁇ m, preferably 13 to 17 ⁇ m. If Ra is less than 10 ⁇ m, it is difficult to polish the ring surface, and the surface roughness below this does not affect the whisker, and if it is more than 20 ⁇ m, whiskers tend to occur.
  • the polishing method of the side and top surfaces of the marking ring is preferably polished using two or more selected from a wire brush, a blast treatment, and a vertical polishing machine.
  • a blast processing apparatus it is possible to perform polishing processing of minute uneven portions.
  • blasting can be applied to workpieces made of inorganic materials such as metals, glass and ceramics, synthetic resins such as plastics, other resins, wood, rocks, and other various materials.
  • inorganic materials such as metals, glass and ceramics, synthetic resins such as plastics, other resins, wood, rocks, and other various materials.
  • spraying at a certain angle and speed optimum polishing is possible even when the processed surface has a deformed portion.
  • Tg is the glass transition temperature.
  • the heat of the engraved ring in the emboss roll causes heat transfer to the embossed back roll through the optical film, and end elongation such that the back surface of the optical film extends.
  • the surface temperature of the embossed back roll within the range of 10 to 50 ° C., the end elongation can be prevented, and it is more preferably 20 ° C. or higher and 40 ° C. or lower. If the surface temperature of the embossed back roll is lowered below 10 ° C., the embossing processability is deteriorated. Further, when the surface temperature of the embossing roll is raised above 50 ° C., end elongation occurs.
  • the width B of the embossed portion according to the present invention is not particularly limited, but is 5 to 30 mm, preferably 10 to 25 mm, particularly preferably 15 to 20 mm.
  • the location of the embossed portion either the inside or outside of the width for applying the optical functional layer may be used.
  • the position of the embossed portion is not particularly limited, but it is preferable that embossing is applied to a portion of 0 to 30 mm from the end in the width direction of the optical film.
  • it is preferable to provide the said embossing part not only in the optical film edge part but in the inner side. That is, it is also preferable to provide a plurality of embossed portions on the optical film.
  • embossed portion according to the present invention may be formed on at least one surface of the film, or may be formed on both surfaces.
  • the height of the embossed portion on the core side is higher than the height of the embossed portion on the outside of the winding, and the difference in height is preferably in the range of 10 to 20 ⁇ m, more preferably in the range of 3 to 8 ⁇ m.
  • the pressing pressure or temperature of the embossing roll so as to be a combination of the core-side embossing height (15 ⁇ m) / winding center embossing height (10 ⁇ m) / winding outer embossing height (5 ⁇ m), etc.
  • the pressing pressure or temperature of the embossing roll so as to be a combination of the core-side embossing height (15 ⁇ m) / winding center embossing height (10 ⁇ m) / winding outer embossing height (5 ⁇ m), etc.
  • the winding pressure in the direction of the core when the optical film is rolled up is 2.0 to 5.0 MPa when the winding length is 3,900 m to 9,000 m.
  • the average height H of the convex portions from the film surface is preferably 0.1 to 3 ⁇ m, and more preferably 0.5 to 2.0 ⁇ m. If it is smaller than 0.1 ⁇ m, the film interlayer height is low, and sticking failure is likely to occur. If it is larger than 3 ⁇ m, winding tightening will occur.
  • the standard deviation of the average height H when the above winding pressure is applied to the optical film is preferably 0.1 to 2.0 ⁇ m.
  • embossing accuracy is practically difficult and workability is difficult, and when it is larger than 2.0 ⁇ m, the difference in right and left diameters of the original winding becomes large, causing the loosening of the winding. It becomes.
  • the elongation of the embossed part is preferably in the range of 0.1 to 0.5%.
  • the embossing range is narrowed and rib formation becomes insufficient.
  • the elongation is larger than 0.5%, workability in subsequent processes such as coating is deteriorated.
  • any core can be used.
  • the plastic material is preferably a hollow plastic core, and the plastic material may be any heat-resistant plastic that can withstand the heat treatment temperature.
  • phenol resin, xylene examples thereof include resins such as resins, melamine resins, polyester resins, and epoxy resins.
  • a thermosetting resin reinforced with a filler such as glass fiber is preferable.
  • the method for producing an optical film of the present invention is formed after a step of forming a resin, which is a raw material for a long optical film serving as a substrate, by a solution casting film forming method or a melt extrusion film forming method. It is preferable to perform an embossing process on the resulting film and then perform a winding process. Furthermore, the application of the optical functional layer is preferably performed during the period from the film forming process of the optical film serving as the substrate to the winding process. By doing in this way, the process to wind up can be performed at once and the roll-shaped optical film which suppressed generation
  • FIG. 5 shows an embodiment of an optical film manufacturing apparatus using the optical film manufacturing method according to the present invention, but the present invention is not limited to this.
  • a preliminarily prepared thermoplastic resin solution is cast on a casting belt 8 from a die 7 to form a web (a film containing a residual solvent after casting a dope on a metal support is called a web).
  • the web is stretched by the tenter 9 and dried by the film drying apparatus 10.
  • the stretched web forms an embossed portion on the web by an embossing roll 61 having irregularities formed on the surface and an embossing back roll 62 facing the embossing roll 61. Thereafter, the film on which the embossed portion is formed is wound up by the winding roll 11.
  • the embossing roll 61 and the embossing back roll 62 are installed behind the film drying apparatus 10, but any of the winding rolls 11 after the web is peeled off from the casting belt 8 can be used. You may install in the place. That is, the embossed film may be dried by the drying device 10. Moreover, when apply
  • coating an optical function layer after applying the optical function layer after the film drying apparatus 10, after drying the optical function layer, it should just wind with the winding roll 11.
  • the optical functional layer When the optical functional layer is applied in multiple layers, after the optical functional layer is dried, the next optical functional layer is applied and dried, and this process is repeated many times to form a multilayer optical functional layer. Then, the winding roll 11 may be wound. Further, after the optical functional layer is formed, the embossed portion may be formed in front of the take-up roll 11.
  • Base film The film used as the base material that can be used in the present invention (when the optical functional layer is not applied, the base film becomes an optical film) will be described.
  • the base film used in the present invention it is preferable that it is easy to manufacture, has good adhesion to the optical functional layer, is optically isotropic, is optically transparent, and the like. Listed as a requirement. Transparent means that the transmittance of visible light is 60% or more, preferably 80% or more, particularly preferably 90% or more.
  • the base film used in the present invention is at least one resin selected from cellulose ester resin, polyester resin, acrylic resin, polycarbonate resin, polyethersulfone resin, polyacrylate resin, norbornene resin, and acrylic styrene resin. preferable.
  • cellulose ester film for example, cellulose ester film, polyester film, polycarbonate film, polyarylate film, polysulfone (including polyethersulfone) film, polyethylene terephthalate, polyethylene naphthalate polyester film, polyethylene film, polypropylene film, cellophane, Cellulose diacetate film, cellulose triacetate, cellulose acetate butyrate film, polyvinylidene chloride film, polyvinyl alcohol film, ethylene vinyl alcohol film, syndiotactic polystyrene film, polycarbonate film, cycloolefin polymer film (Arton (manufactured by JSR)) ZEONEX, ZEONEA Ltd.)), polymethyl pentene film, polyether ketone film, polyether ketone imide film, a polyamide film, a fluororesin film, a nylon film, polymethyl methacrylate film, acrylic film or a glass plate or the like.
  • polysulfone including polyethersulf
  • a cellulose triacetate film, a polycarbonate film, and a polysulfone (including polyethersulfone) film are preferable, and in the present invention, in particular, a cellulose ester film (for example, Konicattak product names KC8UX2MW, KC4UX2MW, KC8UY, KC4UY, KC5UN, KC12UR ( Konica Minolta Opto Co., Ltd.)) is preferably used from the viewpoints of production, cost, transparency, isotropy, adhesion and the like.
  • These films may be films produced by melt casting film formation or films produced by solution casting film formation.
  • those having a retardation Rt in the film thickness direction of 0 nm to 300 nm and a retardation Ro in the in-plane direction of 0 nm to 1000 nm are preferably used.
  • a cellulose ester film As the cellulose ester, cellulose acetate, cellulose acetate butyrate, and cellulose acetate propionate are preferable. Among them, cellulose acetate butyrate, cellulose acetate phthalate, and cellulose acetate propionate are preferably used.
  • X and Y are active ray curable resin layers on a base film having a mixed fatty acid ester of cellulose in the following range And an optical film provided with an antireflection layer is preferably used.
  • a film containing an acrylic resin and a cellulose ester as the base film.
  • a synthetic film containing these a supple film is obtained.
  • the mass ratio of the acrylic resin and the cellulose ester is preferably 95: 5 to 30:70.
  • the mass ratio of the cellulose ester is less than 5% by mass, it becomes brittle, and when it is greater than 70% by mass, the properties of the acrylic resin cannot be sufficiently expressed.
  • the molecular weight of the acrylic resin is preferably 80000 or more, and the molecular weight of the cellulose ester is preferably 75000 or more. When the molecular weight of the acrylic resin is less than 80000, it becomes brittle, and when the molecular weight of the cellulose ester is less than 75000, it becomes brittle.
  • the total substitution degree (T) of the acyl group of the cellulose ester is preferably 2.0 to 3.0, and the substitution degree of the acyl group having 3 to 7 carbon atoms is 1.2 to 3.0. It is preferable. Beyond these ranges, the compatibility deteriorates.
  • the cellulose used as the raw material for the cellulose ester is not particularly limited, and examples thereof include cotton linters, wood pulp (derived from coniferous trees, derived from hardwoods), kenaf and the like. . Moreover, the cellulose ester obtained from them can be mixed and used in arbitrary ratios, respectively.
  • the acylating agent is an acid anhydride (acetic anhydride, propionic anhydride, butyric anhydride)
  • these cellulose esters use an organic solvent such as acetic acid or an organic solvent such as methylene chloride, and It can be obtained by reacting with a cellulose raw material using a protic catalyst.
  • the reaction is carried out using a basic compound such as an amine as a catalyst. Specifically, it can be synthesized with reference to the method described in JP-A-10-45804.
  • the cellulose ester used in the present invention is obtained by mixing and reacting the amount of the acylating agent in accordance with the degree of substitution.
  • these acylating agents react with hydroxyl groups of cellulose molecules.
  • Cellulose molecules are composed of many glucose units linked together, and the glucose unit has three hydroxyl groups. The number of acyl groups derived from these three hydroxyl groups is called the degree of substitution (mol%).
  • cellulose triacetate has acetyl groups bonded to all three hydroxyl groups of the glucose unit (actually 2.6 to 3.0).
  • a mixed fatty acid ester of cellulose in which a propionate group or a butyrate group is bonded in addition to an acetyl group such as cellulose acetate propionate, cellulose acetate butyrate, or cellulose acetate propionate butyrate are also preferably used.
  • the butyryl group forming butyrate may be linear or branched.
  • Cellulose acetate propionate containing a propionate group as a substituent has excellent water resistance and is useful as a film for liquid crystal image display devices.
  • the method for measuring the substitution degree of the acyl group can be measured in accordance with the provisions of ASTM-D817-96.
  • the number average molecular weight of the cellulose ester is preferably 70000 to 250,000, since it has high mechanical strength when molded and an appropriate dope viscosity, and more preferably 80000 to 150,000.
  • cellulose esters are pressurized by applying a cellulose ester solution (dope) generally called a solution casting film forming method onto, for example, an endless metal belt for infinite transport or a support for casting of a rotating metal drum. It is preferable to manufacture the dope from a die by casting (casting).
  • a cellulose ester solution generally called a solution casting film forming method onto, for example, an endless metal belt for infinite transport or a support for casting of a rotating metal drum. It is preferable to manufacture the dope from a die by casting (casting).
  • the organic solvent used for preparing these dopes it is preferable that the cellulose ester can be dissolved and has an appropriate boiling point.
  • the cellulose ester can be dissolved and has an appropriate boiling point.
  • methylene chloride methyl acetate, ethyl acetate, amyl acetate, methyl acetoacetate, acetone, tetrahydrofuran 1,3-dioxolane, 1,4-dioxane, cyclohexanone, ethyl formate, 2,2,2-trifluoroethanol, 2,2,3,3-tetrafluoro-1-propanol, 1,3-difluoro-2 -Propanol, 1,1,1,3,3,3-hexafluoro-2-methyl-2-propanol, 1,1,1,3,3,3-hexafluoro-2-propanol, 2,2,3 , 3,3-pentafluoro-1-propanol, nitroethane, 1,3-dimethyl
  • organic halogen compounds such as methylene chloride, dioxolane derivatives, methyl acetate, ethyl acetate, acetone, methyl acetoacetate, and the like are preferable organic solvents (i.e., good solvent), and as.
  • the boiling point of the organic solvent used is 30-80.
  • the boiling point of the good solvent described above is, for example, methylene chloride (boiling point 40.4 ° C.), methyl acetate (boiling point 56.32 ° C.), acetone (boiling point 56.3 ° C.), ethyl acetate (boiling point 76. 82 ° C.).
  • methylene chloride or methyl acetate having excellent solubility is preferably used.
  • the organic solvent it is preferable to contain 0.1% by mass to 40% by mass of an alcohol having 1 to 4 carbon atoms. It is particularly preferable that the alcohol is contained at 5 to 30% by mass.
  • the solvent After casting the dope described above onto a casting support, the solvent starts to evaporate and the alcohol ratio increases and the web (dope film) gels, making the web strong and peeling from the casting support. It is also used as a gelling solvent for facilitating the dissolution, and when these ratios are small, it also has a role of promoting dissolution of the cellulose ester of the non-chlorine organic solvent.
  • Examples of the alcohol having 1 to 4 carbon atoms include methanol, ethanol, n-propanol, iso-propanol, n-butanol, sec-butanol, tert-butanol and the like.
  • ethanol is preferred because it has good dope stability, relatively low boiling point, good drying properties, and no toxicity. It is preferable to use a solvent containing 5% by mass to 30% by mass of ethanol with respect to 70% by mass to 95% by mass of methylene chloride. Methyl acetate can be used in place of methylene chloride. At this time, the dope may be prepared by a cooling dissolution method.
  • the cellulose ester film used in the present invention is preferably stretched at least in the width direction.
  • the cellulose ester film is 1.01 times to the width direction.
  • the film is preferably stretched 1.5 times. More preferably, it is biaxially stretched in the width direction and the longitudinal direction, and when the residual solvent is 3% by mass to 40% by mass, 1.01 to 1.5 times in the width direction and the longitudinal direction, respectively. It is desirable to be stretched. By doing in this way, the light diffusable film excellent in planarity and light diffusibility can be obtained.
  • the residual solvent amount is represented by the following formula.
  • Residual solvent amount (% by mass) ⁇ (MN) / N ⁇ ⁇ 100
  • M is the mass of the web (cellulose ester film containing the solvent) at an arbitrary point in time
  • N is the mass when the web of M is dried at 110 ° C. for 3 hours.
  • the biaxially stretched cellulose ester film preferably has a light transmittance of 90% or more, more preferably 93% or more.
  • an embossed portion is formed on the film by an embossing roll having irregularities formed on the surface and an embossing roll facing the embossing roll.
  • the surface temperature of the embossing roll is preferably adjusted in relation to the melting point of the base film and the glass transition point.
  • the melting point of TAC triacetyl cellulose
  • the glass transition temperature is 107.
  • the surface temperature of the embossing roll is preferably adjusted between 204 ° C. and 251 ° C.
  • the substrate film according to the present invention preferably has a thickness of 15 to 100 ⁇ m, more preferably 20 to 80 ⁇ m, and moisture permeability was measured according to JIS Z 0208 (25 ° C., 90% RH).
  • the value is preferably 200 g / m 2 ⁇ 24 hours or less, more preferably 10 to 180 g / m 2 ⁇ 24 hours or less, and particularly preferably 160 g / m 2 ⁇ 24 hours or less.
  • the film thickness is 20 to 80 ⁇ m and the moisture permeability is within the above range.
  • the base film according to the present invention is used as a long film, and specifically has a thickness of about 500 m to 8000 m and is usually provided in a roll shape.
  • the width of the base film is preferably 1 to 4 m.
  • plasticizers include phosphate ester plasticizers, phthalate ester plasticizers, trimellitic acid ester plasticizers, pyromellitic acid plasticizers, glycolate plasticizers, citrate ester plasticizers, and polyesters.
  • a plasticizer or the like can be preferably used.
  • phosphate plasticizers triphenyl phosphate, tricresyl phosphate, cresyl diphenyl phosphate, octyl diphenyl phosphate, diphenylbiphenyl phosphate, trioctyl phosphate, tributyl phosphate, etc.
  • phthalate ester plasticizers diethyl phthalate, dimethoxy Ethyl phthalate, dimethyl phthalate, dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, butyl benzyl phthalate, diphenyl phthalate, dicyclohexyl phthalate, and other trimellitic plasticizers such as tributyl trimellitate, triphenyl trimellitate, triethyl
  • trimellitate such as trimellitate, tetrabutyl pyromellitate, tetrafluoro
  • glycolate plasticizers such as nilpyromellitate and tetraethylpyromellitate, triacetin, tributyrin, ethylphthalylethyl glycolate, methylphthalylethyl glycolate, butylphthalylbutyl glycolate, etc., citrate plasticizer
  • polyester plasticizer a copolymer of a dibasic acid and a glycol such as an aliphatic dibasic acid, an alicyclic dibasic acid, or an aromatic dibasic acid can be used.
  • the aliphatic dibasic acid is not particularly limited, and adipic acid, sebacic acid, phthalic acid, terephthalic acid, 1,4-cyclohexyl dicarboxylic acid and the like can be used.
  • glycol ethylene glycol, diethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butylene glycol, 1,3-butylene glycol, 1,2-butylene glycol and the like can be used. These dibasic acids and glycols may be used alone or in combination of two or more.
  • the amount of these plasticizers to be used is preferably 1% by mass to 20% by mass, particularly preferably 3% by mass to 13% by mass with respect to the cellulose ester in terms of film performance, processability and the like.
  • the content is at least 1% by mass or more, preferably 2% by mass or more.
  • an ultraviolet absorber is preferably used for the optical film of the present invention.
  • the ultraviolet absorber those which are excellent in the ability to absorb ultraviolet rays having a wavelength of 370 nm or less and have little absorption of visible light having a wavelength of 400 nm or more are preferably used from the viewpoint of good liquid crystal display properties.
  • ultraviolet absorber preferably used in the present invention include oxybenzophenone compounds, benzotriazole compounds, salicylic acid ester compounds, benzophenone compounds, cyanoacrylate compounds, nickel complex compounds, and the like. However, it is not limited to these.
  • benzotriazole-based ultraviolet absorbers examples include the following ultraviolet absorbers as specific examples, but the present invention is not limited thereto.
  • UV-1 2- (2'-hydroxy-5'-methylphenyl) benzotriazole
  • UV-2 2- (2'-hydroxy-3 ', 5'-di-tert-butylphenyl) benzotriazole
  • UV-3 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) benzotriazole
  • UV-4 2- (2'-hydroxy-3 ', 5'-di-tert-butylphenyl)- 5-Chlorobenzotriazole
  • UV-5 2- (2′-hydroxy-3 ′-(3 ′′, 4 ′′, 5 ′′, 6 ′′ -tetrahydrophthalimidomethyl) -5′-methylphenyl) benzotriazole
  • UV-6 2,2-methylenebis (4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol)
  • UV-7 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) -5-ch
  • UV-10 2,4-dihydroxybenzophenone
  • UV-11 2,2'-dihydroxy-4-methoxybenzophenone
  • UV-12 2-hydroxy-4-methoxy-5-sulfobenzophenone
  • UV-13 Bis (2-methoxy -4-hydroxy-5-benzoylphenylmethane)
  • a benzotriazole-based ultraviolet absorber and a benzophenone-based ultraviolet absorber that are highly transparent and excellent in preventing the deterioration of the polarizing plate and the liquid crystal are preferable, and unnecessary coloring is less.
  • a benzotriazole-based ultraviolet absorber is particularly preferably used.
  • the ultraviolet absorber having a distribution coefficient of 9.2 or more described in JP-A No. 2001-187825 improves the surface quality of a long film and is excellent in coating properties.
  • polymer ultraviolet absorbers described in the general formula (1) or general formula (2) described in JP-A-6-148430 and the general formulas (3), (6) and (7) of Japanese Patent Application No. 2000-156039 Alternatively, an ultraviolet absorbing polymer is also preferably used.
  • PUVA-30M manufactured by Otsuka Chemical Co., Ltd.
  • the like are commercially available.
  • fine particles similar to those described in the coating layer containing an actinic radiation curable resin can be used.
  • the primary average particle diameter of the fine particles added to the cellulose ester film used in the present invention is preferably 20 nm or less, more preferably 5 to 16 nm, and particularly preferably 5 to 12 nm.
  • These fine particles preferably form secondary particles having a particle size of 0.1 to 5 ⁇ m and are contained in the cellulose ester film, and the preferable average particle size is 0.1 to 2 ⁇ m, more preferably 0.2 to 0.6 ⁇ m.
  • irregularities having a height of about 0.10 to 20 ⁇ m are formed on the film surface, thereby providing appropriate slipperiness to the film surface.
  • the primary average particle size of the fine particles used in the present invention is measured by observing particles with a transmission electron microscope (magnification 500,000 to 2,000,000 times), observing 100 particles, and using the average value, The average particle size was taken.
  • the apparent specific gravity of the fine particles is preferably 70 g / liter or more, more preferably 90 to 200 g / liter, and particularly preferably 100 to 200 g / liter.
  • a larger apparent specific gravity makes it possible to make a high-concentration dispersion, which improves haze and agglomerates, and is preferable when preparing a dope having a high solid content concentration as in the present invention.
  • Silicon dioxide fine particles having an average primary particle diameter of 20 nm or less and an apparent specific gravity of 70 g / liter or more are, for example, a mixture of vaporized silicon tetrachloride and hydrogen burned in air at 1000 to 1200 ° C. Can be obtained. For example, it is marketed with the brand name of Aerosil 200V and Aerosil R972V (above, Nippon Aerosil Co., Ltd. product), and can use them.
  • the apparent specific gravity described above is calculated by the following equation by taking a certain amount of silicon dioxide fine particles in a graduated cylinder, measuring the weight at this time.
  • Examples of the method for preparing the fine particle dispersion used in the present invention include the following three types.
  • Preparation Method A After stirring and mixing the solvent and fine particles, dispersion is performed with a disperser. This is a fine particle dispersion. The fine particle dispersion is added to the dope solution and stirred.
  • Preparation Method B After stirring and mixing the solvent and fine particles, dispersion is performed with a disperser. This is a fine particle dispersion. Separately, a small amount of cellulose triacetate is added to the solvent and dissolved by stirring. The fine particle dispersion is added to this and stirred. This is a fine particle addition solution. The fine particle additive solution is sufficiently mixed with the dope solution using an in-line mixer.
  • Preparation Method C Add a small amount of cellulose triacetate to the solvent and dissolve with stirring. Fine particles are added to this and dispersed by a disperser. This is a fine particle addition solution. The fine particle additive solution is sufficiently mixed with the dope solution using an in-line mixer.
  • Preparation method A is excellent in dispersibility of silicon dioxide fine particles
  • preparation method C is excellent in that silicon dioxide fine particles are difficult to re-aggregate.
  • the preparation method B described above is a preferable preparation method that is excellent in both dispersibility of the silicon dioxide fine particles and difficulty in reaggregation of the silicon dioxide fine particles.
  • the concentration of silicon dioxide when the silicon dioxide fine particles are mixed with a solvent and dispersed is preferably 5% by mass to 30% by mass, more preferably 10% by mass to 25% by mass, and most preferably 15% by mass to 20% by mass.
  • a higher dispersion concentration is preferable because liquid turbidity with respect to the added amount tends to be low, and haze and aggregates are improved.
  • the solvent used is preferably lower alcohols such as methyl alcohol, ethyl alcohol, propyl alcohol, isopropyl alcohol, butyl alcohol and the like. Although it does not specifically limit as solvents other than a lower alcohol, It is preferable to use the solvent used at the time of film forming of a cellulose ester.
  • the amount of silicon dioxide fine particles added to the cellulose ester is preferably 0.01 parts by mass to 5.0 parts by mass and more preferably 0.05 parts by mass to 1.0 part by mass with respect to 100 parts by mass of the cellulose ester. Preferably, 0.1 part by weight to 0.5 part by weight is most preferable. The larger the added amount, the better the dynamic friction coefficient, and the smaller the added amount, the less aggregates.
  • Disperser can be a normal disperser. Dispersers can be broadly divided into media dispersers and medialess dispersers. For dispersing silicon dioxide fine particles, a medialess disperser is preferred because of its low haze. Examples of the media disperser include a ball mill, a sand mill, and a dyno mill. Examples of the medialess disperser include an ultrasonic type, a centrifugal type, and a high pressure type. In the present invention, a high pressure disperser is preferable.
  • the high pressure dispersion device is a device that creates special conditions such as high shear and high pressure by passing a composition in which fine particles and a solvent are mixed at high speed through a narrow tube.
  • the maximum pressure condition inside the apparatus is preferably 9.807 MPa or more in a thin tube having a tube diameter of 1 to 2000 ⁇ m. More preferably, it is 19.613 MPa or more. Further, at that time, those having a maximum reaching speed of 100 m / second or more and those having a heat transfer speed of 420 kJ / hour or more are preferable.
  • the high-pressure dispersing apparatus examples include an ultra-high pressure homogenizer (trade name: Microfluidizer) manufactured by Microfluidics Corporation, or a nanomizer manufactured by Nanomizer, and other manton gorin type high-pressure dispersing apparatuses such as a homogenizer manufactured by Izumi Food Machinery. And UHN-01 manufactured by Sanwa Machinery Co., Ltd.
  • casting a dope containing fine particles so as to be in direct contact with the casting support is preferable because a film having high slip properties and low haze can be obtained.
  • the film is peeled off, dried and wound into a roll, and then the optical thin film layer according to the present invention is provided.
  • packaging is usually performed in order to protect the product from dirt, static electricity, and the like.
  • the packaging material is not particularly limited as long as the above purpose can be achieved, but a material that does not hinder volatilization of the residual solvent from the film is preferable.
  • Specific examples include polyethylene, polyester, polypropylene, nylon, polystyrene, paper, various non-woven fabrics, and the like. Those in which the fibers are mesh cloth are more preferably used.
  • the cellulose ester film used in the present invention may have a multilayer structure by a co-casting method using a plurality of dopes.
  • Co-casting is a sequential multilayer casting method in which two or three layers are configured through different dies, and a simultaneous multilayer casting method in which two or three slits are combined in a die having two or three slits. Any of the multilayer casting methods combining sequential multilayer casting and simultaneous multilayer casting may be used.
  • the cellulose ester used in the present invention is preferably used as a support having a small amount of bright spot foreign matter when formed into a film.
  • the bright spot foreign material is a structure in which two polarizing plates are arranged orthogonally (crossed Nicols), a cellulose ester film is arranged between them, and light from a light source is applied from one side to the other side. When the cellulose ester film is observed, the light from the light source appears to leak.
  • the polarizing plate used for the evaluation at this time is preferably composed of a protective film having no bright spot foreign matter, and preferably a glass plate is used for protecting the polarizer.
  • the occurrence of bright spot foreign matter is considered to be one of the causes of unacetylated cellulose contained in the cellulose ester.
  • the use of cellulose ester with a small amount of unacetylated cellulose It can be removed and reduced by filtering the dissolved dope solution. Further, the thinner the film thickness, the smaller the number of bright spot foreign matter per unit area, and the lower the content of cellulose ester contained in the film, the fewer bright spot foreign matter.
  • the bright spot foreign matter having a bright spot diameter of 0.01 mm or more is preferably 200 pieces / cm 2 or less, more preferably 100 pieces / cm 2 or less, 50 pieces / cm 2 or less, 30 pieces / cm. 2 or less, preferably 10 pieces / cm 2 or less, but it is particularly preferred that a 0.
  • the bright spots of 0.005 mm to 0.01 mm are preferably 200 pieces / cm 2 or less, more preferably 100 pieces / cm 2 or less, 50 pieces / cm 2 or less, 30 pieces / cm 2 or less.
  • the number is preferably 10 / cm 2 or less, but particularly preferred is the case where the bright spot is zero. A thing with few also about a bright spot of 0.005 mm or less is preferable.
  • the filter medium conventionally known materials such as glass fibers, cellulose fibers, filter paper, and fluororesins such as tetrafluoroethylene resin are preferably used, but ceramics, metals and the like are also preferably used.
  • the absolute filtration accuracy is preferably 50 ⁇ m or less, more preferably 30 ⁇ m or less, and 10 ⁇ m or less, and particularly preferably 5 ⁇ m or less.
  • the filter medium can be either a surface type or a depth type, but the depth type is preferably used because it is relatively less clogged.
  • the optical functional layer of the present invention is preferably an antireflection layer provided on the hard coat layer.
  • the antireflection layer or other thin film of the present invention may be formed directly on the substrate film, but may be formed thereon via another layer.
  • examples of the coating layer (thin film forming side coating layer, optical functional layer) applied to the surface on the thin film forming side of the base film include a hard coat layer, an antiglare layer, an adhesive layer, an antistatic layer, and the like.
  • a hard coat layer, an antiglare layer, and an antistatic layer are preferably applied, and in the case of the optical film of the present invention, in particular, in order to increase the surface hardness of the optical film, the “other layer” Is preferably provided.
  • a back coat layer may be provided on the side where the antireflection layer or other thin film is formed and on the side opposite to the base film.
  • a hard coat layer used for an optical film will be described as a coating layer as an “other layer” useful for the present invention.
  • the hard coat layer is preferably a layer containing an ultraviolet curable compound (resin) that is cured by ultraviolet rays, and an antireflection film having excellent scratch resistance can be obtained.
  • an ultraviolet curable compound resin
  • the ultraviolet curable resin layer of the hard coat layer is preferably a resin layer formed by polymerizing a component containing an ethylenically unsaturated monomer.
  • the ultraviolet curable resin layer refers to a layer mainly composed of a resin which is cured through a crosslinking reaction or the like by irradiation with an active ray such as an electron beam in addition to ultraviolet rays.
  • Typical examples of the ultraviolet curable resin include an ultraviolet curable resin and an electron beam curable resin, but a resin that is cured by irradiation with active rays other than ultraviolet rays and electron beams may be used.
  • Examples of the ultraviolet curable resin include an ultraviolet curable acrylic urethane resin, an ultraviolet curable polyester acrylate resin, an ultraviolet curable epoxy acrylate resin, an ultraviolet curable polyol acrylate resin, and an ultraviolet curable epoxy resin. be able to.
  • UV-curable acrylic urethane resins are obtained by reacting a polyester polyol with an isocyanate monomer or a prepolymer and further adding 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate (hereinafter referred to as acrylate, methacrylate). And can be easily obtained by reacting an acrylate monomer having a hydroxyl group such as 2-hydroxypropyl acrylate (see, for example, JP-A-59-151110).
  • UV curable polyester acrylate resins can be easily obtained by reacting polyester polyol with 2-hydroxyethyl acrylate and 2-hydroxy acrylate monomers (see, for example, JP-A-59-151112). .
  • ultraviolet curable epoxy acrylate resins include those obtained by reacting epoxy acrylate with an oligomer, a reactive diluent and a photoreaction initiator added thereto (for example, JP-A-1- No. 105738).
  • a photoreaction initiator for example, JP-A-1- No. 105738.
  • the photoinitiator one or more kinds selected from benzoin derivatives, oxime ketone derivatives, benzophenone derivatives, thioxanthone derivatives and the like can be selected and used.
  • ultraviolet curable polyol acrylate resins include trimethylolpropane triacrylate, ditrimethylolpropane tetraacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, alkyl-modified dipentaerythritol pentaacrylate. Etc.
  • the said photoinitiator can also be used as a photosensitizer.
  • specific examples include acetophenone, benzophenone, hydroxybenzophenone, Michler's ketone, ⁇ -amyloxime ester, thioxanthone, and the like.
  • a sensitizer such as n-butylamine, triethylamine, tri-n-butylphosphine can be used.
  • the photoreaction initiator or photosensitizer contained in the ultraviolet curable resin composition excluding the solvent component that volatilizes after coating and drying can be added in an amount of usually 1 to 10% by mass of the composition, and 2.5 to 6 It is preferable that it is mass%.
  • the resin monomer may include general monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, vinyl acetate, benzyl acrylate, cyclohexyl acrylate, and styrene as monomers having one unsaturated double bond.
  • Monomers having two or more unsaturated double bonds include ethylene glycol diacrylate, propylene glycol diacrylate, divinylbenzene, 1,4-cyclohexane diacrylate, 1,4-cyclohexyldimethyl adiacrylate, and the above-mentioned trimethylolpropane. Examples thereof include triacrylate and pentaerythritol tetraacryl ester.
  • Adekaoptomer KR / BY series KR-400, KR-410, KR-550, KR-566, KR-567, BY-320B (manufactured by Asahi Denka Kogyo Co., Ltd.) Or KOHEI Hard A-101-KK, A-101-WS, C-302, C-401-N, C-501, M-101, M-102, T-102, D-102, NS-101, FT -102Q8, MAG-1-P20, AG-106, M-101-C (from Guangei Chemical Industry Co., Ltd.), or Seika Beam PHC2210 (S), PHCX-9 (K-3), PHC2213, DP-10 , DP-20, DP-30, P1000, P1100, P1200, P1300, P1400, P1500, P1600, SCR900 (above, large Manufactured by Seika Kogyo Co., Ltd.
  • the UV curable resin layer can be applied by a known method.
  • the solvent for coating the ultraviolet curable resin layer for example, it can be appropriately selected from hydrocarbons, alcohols, ketones, esters, glycol ethers, and other solvents, or a mixture thereof can be used.
  • propylene glycol mono (alkyl group having 1 to 4 carbon atoms) alkyl ether, preferably propylene glycol mono (alkyl group having 1 to 4 carbon atoms) alkyl ether ester is 5% by mass or more, more preferably 5 to 80% by mass.
  • the solvent contained above is used.
  • any light source that generates ultraviolet rays can be used.
  • a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a carbon arc lamp, a metal halide lamp, a xenon lamp, or the like can be used.
  • the irradiation conditions vary depending on individual lamps, but the amount of light irradiated may if 20 ⁇ 10000mJ / cm 2 degrees, preferably 50 ⁇ 2000mJ / cm 2.
  • the near ultraviolet region to the visible light region it can be used by using a sensitizer having an absorption maximum in that region.
  • the UV curable resin composition is coated and dried and then irradiated with UV light from a light source.
  • the irradiation time is preferably 0.5 seconds to 5 minutes, and 3 seconds to 2 from the curing efficiency and work efficiency of the UV curable resin. Minutes are more preferred.
  • inorganic or organic fine particles it is preferable to add inorganic or organic fine particles to the cured film layer thus obtained in order to prevent black bands and to improve the scratch resistance.
  • the inorganic fine particles include silicon oxide, titanium oxide, aluminum oxide, tin oxide, zinc oxide, calcium carbonate, barium sulfate, talc, kaolin, calcium sulfate, and the like, and examples of the organic fine particles include polymethacrylic acid.
  • Methyl acrylate resin powder acrylic styrene resin powder, polymethyl methacrylate resin powder, silicon resin powder, polystyrene resin powder, polycarbonate resin powder, benzoguanamine resin powder, melamine resin powder, polyolefin resin powder, polyester resin powder
  • Polyamide-based resin powder, polyimide-based resin powder, or polyfluorinated ethylene-based resin powder, and the like can be added to the ultraviolet curable resin composition.
  • the average particle size of these fine particle powders is preferably 0.005 to 5 ⁇ m, more preferably 0.1 to 5.0 ⁇ m, and further preferably 0.1 to 4.0 ⁇ m added to the coating composition for forming the hard coat layer. It is particularly preferable from the viewpoint of the stability of the composition.
  • the proportion of the ultraviolet curable resin composition and the fine particle powder is 0.1 to 30 parts by mass with respect to 100 parts by mass of the resin composition.
  • the layer formed by curing the ultraviolet curable resin formed in this way is a hard coat layer having a center line average roughness Ra of 1 to 50 nm as defined in JIS B 0601, but Ra is 0.1. It may be an antiglare layer of about 1 ⁇ m.
  • the liquid film thickness (also referred to as wet film thickness) during coating is about 1 to 100 ⁇ m, preferably 0.1 to 30 ⁇ m, more preferably 0.5 to 30 ⁇ m.
  • the dry film thickness is an average film thickness of 0.1 to 30 ⁇ m, preferably 1 to 20 ⁇ m.
  • the base film used in the present invention is preferably provided with a back coat layer containing fine particles on the back side.
  • Examples of the fine particles contained in the backcoat layer useful in the present invention include fine particles of inorganic compounds or fine particles of organic compounds.
  • the particles contained in the backcoat layer are 0.1 to 50% by weight, preferably 0.1 to 10% by weight, based on the binder.
  • the increase in haze is preferably 1% or less, particularly preferably 0 to 0.1%.
  • the organic solvent used in the back coat layer is not particularly limited, but since the anti-curl function can be imparted to the back coat layer, the organic solvent that dissolves the cellulose ester film and the resin of the cellulose ester film material or the organic solvent that swells. Solvents are useful. These may be appropriately selected depending on the curl degree of the cellulose ester film, the type of resin, the mixing ratio, the coating amount, and the like.
  • organic solvent examples include benzene, toluene, xylene, dioxane, acetone, methyl ethyl ketone, N, N-dimethylformamide, methyl acetate, ethyl acetate, N-methylpyrrolidone, 1,3-dimethyl- 2-Imidazolidinone.
  • organic solvent examples include methanol, ethanol, n-propyl alcohol, i-propyl alcohol, and n-butanol, but the organic solvent is not particularly limited thereto.
  • a coating liquid film thickness (sometimes referred to as a wet film thickness) is 1 to 100 ⁇ m using a gravure coater, dip coater, wire bar coater, reverse coater, extrusion coater or the like. In particular, 5 to 30 ⁇ m is preferable.
  • the back coat layer can be applied in two or more steps. Further, the backcoat layer may also serve as an easy adhesion layer for improving the adhesion with the polarizer.
  • Examples of the resin used for the back coat layer include vinyl chloride / vinyl acetate copolymer, vinyl chloride resin, vinyl acetate resin, copolymer of vinyl acetate and vinyl alcohol, partially hydrolyzed vinyl chloride / vinyl acetate copolymer, and chloride.
  • Vinyl homopolymers or copolymers such as vinyl / vinylidene chloride copolymer, vinyl chloride / acrylonitrile copolymer, ethylene / vinyl alcohol copolymer, chlorinated polyvinyl chloride, ethylene / vinyl chloride copolymer, ethylene / vinyl acetate copolymer, cellulose nitrate, cellulose acetate Cellulose ester resins such as propionate, cellulose diacetate, cellulose triacetate, cellulose acetate phthalate, cellulose acetate butyrate resin, maleic acid and / or Is a copolymer of acrylic acid, acrylic acid ester copolymer, acrylonitrile / styrene copolymer, chlorinated polyethylene, acrylonitrile / chlorinated polyethylene / styrene copolymer, methyl methacrylate / butadiene / styrene copolymer, acrylic resin, polyvinyl ace
  • the antireflection layer which is the optical functional layer of the present invention, and the optical film coated therewith will be described.
  • At least one of a metal oxide layer, a metal oxynitride, a metal nitride, an organic polymer, and a liquid crystal compound is formed on the aforementioned base film, It is preferable to do.
  • the antireflection layer may be formed directly on the base film, but at least one hard coat layer or other coating layer may be provided and formed on the base film having an uneven surface. This is a preferred method because it is less likely to be scratched in the process of handling the optical film and the step of making the optical film into a polarizing plate to be described later.
  • the above-mentioned cured resin layer having a center line average surface roughness (Ra) defined by JIS B 0601 of 0.01 to 1 ⁇ m is preferable.
  • These are actinic radiation curable resin layers that are cured by actinic radiation such as ultraviolet rays.
  • An optical film excellent in scratch resistance can be obtained by forming the metal oxide layer according to the present invention on the resin layer cured by such ultraviolet rays.
  • an antireflection layer of an optical film is formed by laminating a high refractive index layer having a refractive index higher than that of the base film and a low refractive index layer having a refractive index lower than that of the base film on the base film.
  • Those laminated in the order of refractive index layer / low refractive index layer are preferably used from the viewpoint of reducing the reflectance.
  • the present invention is not limited only to lamination in this order, and may be reversed, or a medium refractive index layer having a refractive index higher than that of the base film and lower than that of the high refractive index layer during this period.
  • the present invention can also be achieved with a configuration of three or more layers sandwiching.
  • a metal oxide layer particularly preferably used as an example of the antireflection layer of the present invention will be described.
  • the metal oxide layer is preferably used as at least one of a high refractive index layer and a low refractive index layer.
  • the antireflection layer is preferably formed by coating.
  • the base film, the high refractive index layer, and the low refractive index layer preferably have a refractive index that satisfies the following relationship.
  • Refractive index of low refractive index layer ⁇ refractive index of base film ⁇ refractive index of hard coat layer ⁇ refractive index of high refractive index layer
  • an optical film provided with an antiglare antireflection layer by imparting irregularities to the hard coat layer or the high refractive index layer.
  • a layer structure in the order of a base film, a hard coat layer (antiglare layer), a medium refractive index layer, a high refractive index layer, and a low refractive index layer is also a preferable configuration. It is preferable to impart an antiglare property to the low refractive index layer on the surface, and an antiglare layer may be provided on the surface.
  • a high refractive index layer having a refractive index higher than that of the base film is provided between the base film provided with the base film or the hard coat layer and the low refractive index layer. It is preferable to provide it. In addition, it is preferable to provide a middle refractive index layer between the base film and the high refractive index layer in order to reduce the reflectance.
  • the refractive index of the high refractive index layer is preferably 1.55 to 2.30, and more preferably 1.57 to 2.20.
  • the film thickness of the high refractive index layer is preferably 5 nm to 1 ⁇ m, more preferably 10 nm to 0.2 ⁇ m, and most preferably 30 nm to 0.2 ⁇ m from the characteristics of the optical interference layer.
  • the haze of the high refractive index layer is preferably 5% or less, more preferably 3% or less, and most preferably 1% or less.
  • the strength of the high refractive index layer is preferably H or more, more preferably 2H or more, and most preferably 3H or more, with a pencil hardness of 1 kg load.
  • the high refractive index layer preferably contains conductive particles, inorganic particles having a composition different from the conductive particles, and a binder. Either or both of the conductive particles and the inorganic particles may be used.
  • the conductive particles used for the high refractive index layer preferably have a refractive index of 1.60 to 2.60, and more preferably 1.65 to 2.50.
  • the average particle diameter of the primary particles of the conductive particles is preferably 10 to 200 nm, more preferably 20 to 150 nm, and most preferably 30 to 100 nm.
  • the average particle diameter of the conductive fine particles can also be measured from an electron micrograph taken with a scanning electron microscope (SEM) or the like. Further, it may be measured by a particle size distribution meter using a dynamic light confusion method or a static light confusion method. If the particle size is too small, aggregation tends to occur and the dispersibility deteriorates. If the particle size is too large, the haze is remarkably increased.
  • the shape of the conductive particles is preferably a rice grain shape, a spherical shape, a cubic shape, a spindle shape, a needle shape, or an indefinite shape.
  • the amount of conductive particles used is preferably 5 to 85% by mass in the high refractive index layer. It is more preferably 10 to 80% by mass, and most preferably 20 to 75% by mass. If the amount used is small, desired effects such as refractive index and conductivity cannot be obtained, and if it is too large, film strength is deteriorated.
  • the conductive particles are supplied to a coating solution for forming a high refractive index layer in a dispersion state dispersed in a medium.
  • a liquid having a boiling point of 60 to 170 ° C. is preferably used.
  • dispersion solvent examples include water, alcohol (eg, methanol, ethanol, isopropanol, butanol, benzyl alcohol), ketone (eg, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone), ketone alcohol (eg, acetone alcohol) , Esters (eg, methyl acetate, ethyl acetate, propyl acetate, butyl acetate, methyl formate, ethyl formate, propyl formate, butyl formate), aliphatic hydrocarbons (eg, hexane, cyclohexane), halogenated hydrocarbons (eg, methylene) Chloride, chloroform, carbon tetrachloride), aromatic hydrocarbons (eg, benzene, toluene, xylene), amides (eg, dimethylformamide, dimethylacetamide, di
  • the conductive particles can be dispersed in the medium using a disperser.
  • the disperser include a sand grinder mill (eg, a bead mill with pins), a high-speed impeller mill, a pebble mill, a roller mill, an attritor, and a colloid mill.
  • a sand grinder mill and a high-speed impeller mill are particularly preferred.
  • preliminary dispersion processing may be performed.
  • the disperser used for the preliminary dispersion treatment include a ball mill, a three-roll mill, a kneader, and an extruder. It is also preferable to contain a dispersant.
  • the high refractive index layer contains inorganic particles having a composition different from that of the conductive particles.
  • the inorganic particles used are one kind of inorganic particles selected from the group consisting of hollow silica, colloidal silica, and magnesium fluoride.
  • the amount of the inorganic particles used is preferably 1 to 30% by mass in the high refractive index layer, more preferably 3 to 25% by mass, and most preferably 5 to 20% by mass. If the amount used is small, desired effects such as scratch resistance, adhesion, hardness, chemical resistance under high temperature and high humidity cannot be obtained, and if too large, film strength is deteriorated.
  • the high refractive index layer preferably uses a polymer having a crosslinked structure (hereinafter also referred to as a crosslinked polymer) as a binder polymer.
  • the crosslinked polymer include polymers having a saturated hydrocarbon chain such as polyolefin (hereinafter collectively referred to as polyolefin), and crosslinked products such as polyether, polyurea, polyurethane, polyester, polyamine, polyamide, and melamine resin.
  • polyolefin polyolefin
  • crosslinked products such as polyether, polyurea, polyurethane, polyester, polyamine, polyamide, and melamine resin.
  • a crosslinked product of polyolefin, polyether and polyurethane is preferred, a crosslinked product of polyolefin and polyether is more preferred, and a crosslinked product of polyolefin is most preferred.
  • the crosslinked polymer has an anionic group.
  • the anionic group has a function of maintaining the dispersion state of the inorganic fine particles, and the crosslinked structure has a function of imparting a film forming ability to the polymer and strengthening the film.
  • the anionic group may be directly bonded to the polymer chain or may be bonded to the polymer chain via a linking group, but is bonded to the main chain as a side chain via the linking group. Is preferred.
  • anionic group examples include a carboxylic acid group (carboxyl), a sulfonic acid group (sulfo), and a phosphoric acid group (phosphono). Of these, sulfonic acid groups and phosphoric acid groups are preferred.
  • the anionic group may be in a salt state.
  • the cation that forms a salt with the anionic group is preferably an alkali metal ion.
  • the proton of the anionic group may be dissociated.
  • the linking group that connects the anionic group and the polymer chain is preferably a divalent group selected from —CO—, —O—, an alkylene group, an arylene group, and combinations thereof.
  • the crosslinked polymer which is a preferable binder polymer is preferably a copolymer having a repeating unit having an anionic group and a repeating unit having a crosslinked structure.
  • the proportion of the repeating unit having an anionic group in the copolymer is preferably 2 to 96% by mass, more preferably 4 to 94% by mass, and most preferably 6 to 92% by mass. preferable.
  • the repeating unit may have two or more anionic groups.
  • the crosslinked polymer having an anionic group may contain other repeating units (a repeating unit having neither an anionic group nor a crosslinked structure).
  • Other repeating units are preferably a repeating unit having an amino group or a quaternary ammonium group and a repeating unit having a benzene ring.
  • the amino group or quaternary ammonium group has a function of maintaining the dispersed state of the inorganic fine particles, like the anionic group.
  • the benzene ring has a function of increasing the refractive index of the high refractive index layer. The amino group, the quaternary ammonium group, and the benzene ring can obtain the same effect even if they are contained in a repeating unit having an anionic group or a repeating unit having a crosslinked structure.
  • the amino group or quaternary ammonium group may be directly bonded to the polymer chain, or may be a side chain via a linking group. May be bonded to the polymer chain, but the latter is more preferred.
  • the amino group or quaternary ammonium group is preferably a secondary amino group, a tertiary amino group or a quaternary ammonium group, more preferably a tertiary amino group or a quaternary ammonium group.
  • the group bonded to the nitrogen atom of the secondary amino group, tertiary amino group or quaternary ammonium group is preferably an alkyl group, more preferably an alkyl group having 1 to 12 carbon atoms, still more preferably a carbon number. 1 to 6 alkyl groups.
  • the counter ion of the quaternary ammonium group is preferably a halide ion.
  • the linking group that connects the amino group or quaternary ammonium group to the polymer chain is a divalent group selected from —CO—, —NH—, —O—, an alkylene group, an arylene group, and combinations thereof. Is preferred.
  • the ratio is preferably 0.06 to 32% by mass, more preferably 0.08 to 30% by mass, Most preferably, the content is 0.1 to 28% by mass.
  • the cross-linked polymer is prepared by blending a monomer for generating a cross-linked polymer to prepare a coating solution for forming a high refractive index layer and a medium refractive index layer, and is generated by a polymerization reaction simultaneously with or after coating of the coating solution. Is preferred. Each layer is formed with the production of the crosslinked polymer.
  • the monomer having an anionic group functions as a dispersant for inorganic fine particles in the coating solution.
  • the monomer having an anionic group is preferably used in an amount of 1 to 50% by mass, more preferably 5 to 40% by mass, and still more preferably 10 to 30% by mass with respect to the inorganic fine particles.
  • the monomer having an amino group or a quaternary ammonium group functions as a dispersion aid in the coating solution.
  • the monomer having an amino group or a quaternary ammonium group is preferably used in an amount of 3 to 33% by mass based on the monomer having an anionic group.
  • Examples of monomers having two or more ethylenically unsaturated groups include esters of polyhydric alcohols and (meth) acrylic acid (eg, ethylene glycol di (meth) acrylate, 1,4-dichlorohexane diacrylate, penta Erythritol tetra (meth) acrylate, pentaerythritol tri (meth) acrylate, trimethylolpropane tri (meth) acrylate, trimethylolethane tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate , Pentaerythritol hexa (meth) acrylate, 1,2,3-cyclohexanetetramethacrylate, polyurethane polyacrylate, polyester polyacrylate), vinylbenzene and its derivatives For example, 1,4-divinylbenzene, 4-
  • monomers may be used as the monomer having an anionic group and the monomer having an amino group or a quaternary ammonium group.
  • examples of commercially available monomers having an anionic group include KAYAMAPMPM-21, PM-2 (manufactured by Nippon Kayaku Co., Ltd.), Antox MS-60, MS-2N, MS-NH4 (manufactured by Nippon Emulsifier Co., Ltd.).
  • Aronix M-5000, M-6000, M-8000 series (manufactured by Toagosei Chemical Industry Co., Ltd.), Biscote # 2000 series (manufactured by Osaka Organic Chemical Industry Co., Ltd.), New Frontier GX-8289 (Daiichi Kogyo Seiyaku NK ester CB-1, A-SA (manufactured by Shin-Nakamura Chemical Co., Ltd.), AR-100, MR-100, MR-200 (manufactured by Eighth Chemical Co., Ltd.), etc. It is done.
  • Examples of commercially available monomers having a commercially available amino group or quaternary ammonium group include DMAA (manufactured by Osaka Organic Chemical Industry Co., Ltd.), DMAEA, DMAPAA (manufactured by Kojin Co., Ltd.), and Bremer QA (Nippon Yushi Co., Ltd.). And New Frontier C-1615 (Daiichi Kogyo Seiyaku Co., Ltd.).
  • the polymer polymerization reaction can be a photopolymerization reaction or a thermal polymerization reaction.
  • a photopolymerization reaction is particularly preferable.
  • a polymerization initiator is preferably used for the polymerization reaction.
  • the above-mentioned thermal polymerization initiator and photopolymerization initiator used for forming the binder polymer of the hard coat layer may be mentioned.
  • a commercially available polymerization initiator may be used as the polymerization initiator.
  • a polymerization accelerator may be used.
  • the addition amount of the polymerization initiator and the polymerization accelerator is preferably in the range of 0.2 to 10% by mass of the total amount of monomers.
  • the coating liquid (dispersion of inorganic fine particles containing monomer) may be heated to promote polymerization of the monomer (or oligomer). Moreover, it may heat after the photopolymerization reaction after application
  • a polymer having a relatively high refractive index for the high refractive index layer.
  • the polymer having a high refractive index include polystyrene, styrene copolymer, polycarbonate, melamine resin, phenol resin, epoxy resin, and polyurethane obtained by reaction of cyclic (alicyclic or aromatic) isocyanate and polyol. .
  • Polymers having other cyclic (aromatic, heterocyclic, and alicyclic) groups and polymers having halogen atoms other than fluorine as substituents can also be used with a high refractive index.
  • the metal oxide layer is preferably provided by coating a coating solution containing inorganic fine particles containing a metal oxide.
  • a high refractive index layer may be formed from an organometallic compound having film-forming ability.
  • organometallic compound can be dispersed in an appropriate medium or is in a liquid state.
  • organometallic compounds include metal alcoholates (eg, titanium tetraethoxide, titanium tetra-i-propoxide, titanium tetra-n-propoxide, titanium tetra-n-butoxide, titanium tetra-sec-butoxide, titanium Tetra-tert-butoxide, aluminum triethoxide, aluminum tri-i-propoxide, aluminum tributoxide, antimony triethoxide, antimony riboxide, zirconium tetraethoxide, zirconium tetra-i-propoxide, zirconium tetra-n- Propoxide, zirconium tetra-n-butoxide, zirconium tetra-sec-butoxide, zirconium tetra-tert-butoxide), chelate compounds (eg, di-isopropoxytit
  • a layer lower than the refractive index of the base film is referred to as a low refractive index layer.
  • a low-refractive-index layer formed by cross-linking of a fluorine-containing resin that is cross-linked by heat or ionizing radiation hereinafter also referred to as “fluorinated resin before cross-linking”
  • fluorinated resin before cross-linking a low-refractive index layer by a sol-gel method, and particles and a binder polymer
  • a low refractive index layer having voids between or inside the particles is used.
  • the refractive index of the low refractive index layer is low, it is preferable because the antireflection performance is improved, but it is difficult from the viewpoint of imparting strength to the low refractive index layer. From this balance, the refractive index of the low refractive index layer is preferably in the range of 1.30 to 1.45.
  • the film thickness of the low refractive index layer is preferably 5 nm to 0.5 ⁇ m, more preferably 30 nm to 0.2 ⁇ m, from the characteristics as an optical interference layer.
  • fluorine-containing resin before crosslinking include a fluorine-containing copolymer formed from a fluorine-containing vinyl monomer and a monomer for imparting a crosslinkable group.
  • fluorine-containing vinyl monomer unit include, for example, fluoroolefins (for example, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoroethylene, hexafluoropropylene, perfluoro-2,2-dimethyl-1,3 -Dioxoles, etc.), (meth) acrylic acid partial or fully fluorinated alkyl ester derivatives (for example, Biscoat 6FM (Osaka Organic Chemical) or M-2020 (Daikin)), fully or partially fluorinated vinyl ethers, etc.
  • fluoroolefins for example, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoroethylene, hexafluor
  • Examples of the monomer for imparting a crosslinkable group include glycidyl methacrylate, vinyltrimethoxysilane, ⁇ -methacryloyloxypropyltrimethoxysilane, vinylglycidyl ether, and other vinyl monomers having a crosslinkable functional group in advance in the molecule.
  • Vinyl monomers having a carboxyl group, hydroxyl group, amino group, sulfonic acid group, etc. for example, (meth) acrylic acid, methylol (meth) acrylate, hydroxyalkyl (meth) acrylate, allyl acrylate, hydroxyalkyl vinyl ether, hydroxyalkyl allyl) Ether, etc.).
  • crosslinkable group examples include acryloyl, methacryloyl, isocyanate, epoxy, aziridine, oxazoline, aldehyde, carbonyl, hydrazine, carboxyl, methylol, and active methylene group.
  • the fluorine-containing copolymer When the fluorine-containing copolymer is crosslinked by heating with a crosslinking group that reacts by heating, or a combination of an ethylenically unsaturated group and a thermal radical generator or an epoxy group and a thermal acid generator, it is a thermosetting type.
  • a crosslinking group that reacts by heating, or a combination of an ethylenically unsaturated group and a thermal radical generator or an epoxy group and a thermal acid generator
  • it is a thermosetting type.
  • crosslinking by irradiation with light preferably ultraviolet rays, electron beams, etc.
  • the ionizing radiation curable type is used.
  • a fluorine-containing copolymer formed by using a monomer other than the fluorine-containing vinyl monomer and the monomer for imparting a crosslinkable group may be used as the fluorine-containing resin before crosslinking.
  • the monomer that can be used in combination is not particularly limited.
  • olefins ethylene, propylene, isoprene, vinyl chloride, vinylidene chloride, etc.
  • acrylic esters methyl acrylate, methyl acrylate, ethyl acrylate, 2-acrylic acid 2- Ethyl hexyl
  • methacrylic acid esters methyl methacrylate, ethyl methacrylate, butyl methacrylate, ethylene glycol dimethacrylate, etc.
  • styrene derivatives styrene, divinylbenzene, vinyl toluene, ⁇ -methyl styrene, etc.
  • vinyl ethers methyl vinyl ether) Etc.
  • vinyl esters vinyl acetate, vinyl propionate, vinyl cinnamate, etc.
  • acrylamides N-tertbutylacrylamide, N-cyclohexylacrylamide, etc.
  • methacrylamides Ronitoriru derivatives and the like
  • polyorganosiloxane skeleton or a perfluoropolyether skeleton into the fluorinated copolymer in order to impart slipperiness and antifouling properties.
  • polyorganosiloxane or perfluoropolyether having an acrylic group, methacrylic group, vinyl ether group, styryl group or the like at the terminal is polymerized with the above monomer, and polyorganosiloxane or perfluoropolyester having a radical generating group at the terminal. It can be obtained by polymerization of the above monomers with ether, reaction of a polyorganosiloxane or perfluoropolyether having a functional group with a fluorine-containing copolymer, or the like.
  • the proportion of each monomer used to form the fluorinated copolymer before cross-linking is preferably 20 to 70 mol%, more preferably 40 to 70 mol% of the fluorinated vinyl monomer,
  • the amount of the monomer is preferably 1 to 20 mol%, more preferably 5 to 20 mol%, and the other monomer used in combination is preferably 10 to 70 mol%, more preferably 10 to 50 mol%.
  • the fluorine-containing copolymer can be obtained by polymerizing these monomers in the presence of a radical polymerization initiator by means of solution polymerization, bulk polymerization, emulsion polymerization, suspension polymerization or the like.
  • Fluorine-containing resin before crosslinking is commercially available and can be used.
  • Examples of commercially available fluorine-containing resins before cross-linking include Cytop (Asahi Glass), Teflon (registered trademark) AF (DuPont), polyvinylidene fluoride, Lumiflon (Asahi Glass), Opstar (JSR), etc. Can be mentioned.
  • the low refractive index layer comprising a crosslinked fluorine-containing resin as a constituent component preferably has a dynamic friction coefficient in the range of 0.03 to 0.15 and a contact angle with water in the range of 90 to 120 degrees.
  • the low refractive index layer containing a crosslinked fluorine-containing resin as a constituent component contains inorganic particles.
  • inorganic fine particles used in the low refractive index layer amorphous particles are preferably used, and are preferably composed of metal oxides, nitrides, sulfides or halides, and metal oxides are particularly preferable.
  • inorganic fine particles containing two or more metals may be used.
  • Particularly preferred inorganic fine particles are silicon dioxide fine particles, that is, silica fine particles.
  • the average particle size of the inorganic fine particles is preferably 0.001 to 0.2 ⁇ m, and more preferably 0.005 to 0.05 ⁇ m.
  • the particle diameter of the fine particles is preferably as uniform (monodispersed) as possible. If the particle size of the inorganic fine particles is too large, light is scattered and the film becomes opaque. If the particle size is too small, the particles are likely to aggregate and difficult to synthesize and handle.
  • the compounding amount of the inorganic fine particles is preferably 5 to 90% by mass, more preferably 10 to 70% by mass, and particularly preferably 10 to 50% by mass with respect to the total mass of the low refractive index layer.
  • the inorganic fine particles are preferably used after being subjected to a surface treatment.
  • the surface treatment method includes physical surface treatment such as plasma discharge treatment and corona discharge treatment and chemical surface treatment using a coupling agent, but the use of a coupling agent is preferred.
  • an organoalkoxy metal compound eg, titanium coupling agent, silane coupling agent, etc.
  • treatment with a silane coupling agent described later is particularly effective.
  • sol-gel materials can be used as the material for the low refractive index layer.
  • metal alcoholates alcolates such as silane, titanium, aluminum, zirconium, etc.
  • organoalkoxy metal compounds and hydrolysates thereof can be used.
  • alkoxysilane, organoalkoxysilane and its hydrolyzate are preferable.
  • Examples of these include tetraalkoxysilane (tetramethoxysilane, tetraethoxysilane, etc.), alkyltrialkoxysilane (methyltrimethoxysilane, ethyltrimethoxysilane, etc.), aryltrialkoxysilane (phenyltrimethoxysilane, etc.), dialkyl. Examples thereof include dialkoxysilane and diaryl dialkoxysilane.
  • organoalkoxysilanes having various functional groups (vinyl trialkoxysilane, methylvinyl dialkoxysilane, ⁇ -glycidyloxypropyltrialkoxysilane, ⁇ -glycidyloxypropylmethyl dialkoxysilane, ⁇ - (3,4-epoxy) Dicyclohexyl) ethyltrialkoxysilane, ⁇ -methacryloyloxypropyltrialkoxysilane, ⁇ -aminopropyltrialkoxysilane, ⁇ -mercaptopropyltrialkoxysilane, ⁇ -chloropropyltrialkoxysilane, etc.), perfluoroalkyl group-containing silane compounds (for example, it is also preferable to use (heptadecafluoro-1,1,2,2-tetradecyl) triethoxysilane, 3,3,3-trifluoropropyltrimethoxys
  • the low refractive index layer it is also preferable to use a layer formed using microparticles between or within the fine particles using inorganic or organic fine particles.
  • the average particle diameter of the fine particles is preferably from 0.5 to 200 nm, more preferably from 1 to 100 nm, still more preferably from 3 to 70 nm, and most preferably from 5 to 40 nm.
  • the particle diameter of the fine particles is preferably as uniform (monodispersed) as possible.
  • the inorganic fine particles are preferably amorphous.
  • the inorganic fine particles are preferably made of a metal oxide, nitride, sulfide or halide, more preferably a metal oxide or a metal halide, and most preferably a metal oxide or a metal fluoride.
  • metal atoms Na, K, Mg, Ca, Ba, Al, Zn, Fe, Cu, Ti, Sn, In, W, Y, Sb, Mn, Ga, V, Nb, Ta, Ag, Si, B Bi, Mo, Ce, Cd, Be, Pb and Ni are preferable, and Mg, Ca, B and Si are more preferable.
  • An inorganic compound containing two kinds of metals may be used.
  • a particularly preferred inorganic compound is silicon dioxide, ie silica.
  • the microvoids in the inorganic fine particles can be formed, for example, by crosslinking silica molecules forming the particles. Crosslinking silica molecules reduces the volume and makes the particles porous.
  • (Porous) inorganic fine particles having microvoids are prepared by a sol-gel method (described in JP-A No. 53-112732 and Japanese Patent Publication No. 57-9051) or a precipitation method (described in APPLIED OPTICS, Vol. 27, page 3356 (1988)). Can be directly synthesized as a dispersion. Further, the powder obtained by the drying / precipitation method can be mechanically pulverized to obtain a dispersion. Commercially available porous inorganic fine particles (for example, silicon dioxide sol) may be used.
  • the inorganic fine particles having microvoids are preferably used in a state of being dispersed in an appropriate medium in order to form a low refractive index layer.
  • an appropriate medium for example, water, alcohol (for example, methanol, ethanol, isopropyl alcohol) and ketone (for example, methyl ethyl ketone, methyl isobutyl ketone) are preferable.
  • the organic fine particles are also preferably amorphous.
  • the organic fine particles are preferably polymer fine particles synthesized by polymerization reaction of monomers (for example, emulsion polymerization method).
  • the organic fine particle polymer preferably contains a fluorine atom.
  • the proportion of fluorine atoms in the polymer is preferably 35 to 80% by mass, and more preferably 45 to 75% by mass.
  • the ratio of the polyfunctional monomer is more preferably 30 to 80 mol%, and most preferably 35 to 50 mol%.
  • the monomer used for the synthesis of the organic fine particles include fluoroolefins (for example, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoropropylene) as examples of monomers containing fluorine atoms used to synthesize fluorine-containing polymers.
  • fluoroolefins for example, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoropropylene
  • fluoro-2,2-dimethyl-1,3-dioxole fluorinated alkyl esters of acrylic acid or methacrylic acid
  • fluorinated vinyl ethers for example, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoropropylene
  • a copolymer of a monomer containing a fluorine atom and a monomer not containing a fluorine atom may be used.
  • monomers that do not contain fluorine atoms include olefins (eg, ethylene, propylene, isoprene, vinyl chloride, vinylidene chloride), acrylic esters (eg, methyl acrylate, ethyl acrylate, 2-ethylhexyl acrylate).
  • Methacrylic acid esters for example, methyl methacrylate, ethyl methacrylate, butyl methacrylate
  • styrenes for example, styrene, vinyl toluene, ⁇ -methyl styrene
  • vinyl ethers for example, methyl vinyl ether
  • vinyl esters examples thereof include vinyl acetate and vinyl propionate
  • acrylamides for example, N-tert-butylacrylamide, N-cyclohexylacrylamide
  • methacrylamides and acrylonitriles examples thereof include vinyl acetate and vinyl propionate
  • acrylamides for example, N-tert-butylacrylamide, N-cyclohexylacrylamide
  • methacrylamides and acrylonitriles for example, N-tert-butylacrylamide, N-cyclohexylacrylamide
  • polyfunctional monomers examples include dienes (eg, butadiene, pentadiene), esters of polyhydric alcohols and acrylic acid (eg, ethylene glycol diacrylate, 1,4-cyclohexane diacrylate, dipentaerythritol hexaacrylate), Esters of polyhydric alcohol and methacrylic acid (for example, ethylene glycol dimethacrylate, 1,2,4-cyclohexanetetramethacrylate, pentaerythritol tetramethacrylate), divinyl compounds (for example, divinylcyclohexane, 1,4-divinylbenzene), divinyl Examples include sulfones, bisacrylamides (eg, methylenebisacrylamide) and bismethacrylamides.
  • dienes eg, butadiene, pentadiene
  • esters of polyhydric alcohols and acrylic acid eg, ethylene glycol diacrylate, 1,4-cyclohexane di
  • the micro voids between the particles can be formed by stacking at least two fine particles.
  • spherical particles having the same particle diameter (completely monodispersed) are closely packed, microvoids between particles with a porosity of 26% by volume are formed.
  • spherical fine particles having the same particle diameter are simply filled with cubic particles, microvoids between fine particles having a porosity of 48% by volume are formed.
  • the porosity varies considerably from the above theoretical value.
  • the refractive index of the low refractive index layer is lowered.
  • the size of the microvoids can be adjusted to an appropriate value (does not scatter light and cause no problem with the strength of the low refractive index layer) by adjusting the particle size of the fine particles. Can be adjusted. Furthermore, by making the particle diameters of the fine particles uniform, it is possible to obtain an optically uniform low refractive index layer in which the size of microvoids between particles is uniform. Thereby, although the low refractive index layer is microscopically a microvoided porous film, it can be optically or macroscopically uniform.
  • the interparticle microvoids are preferably closed in the low refractive index layer by fine particles and a polymer. The closed air gap also has an advantage that light scattering on the surface of the low refractive index layer is less than that of an opening opened on the surface of the low refractive index layer.
  • the macroscopic refractive index of the low refractive index layer becomes lower than the sum of the refractive indexes of the components constituting the low refractive index layer.
  • the refractive index of the layer is the sum of the refractive indices per volume of the layer components.
  • the refractive index of the constituent component of the low refractive index layer such as fine particles or polymer is larger than 1, whereas the refractive index of air is 1.00. Therefore, a low refractive index layer having a very low refractive index can be obtained by forming microvoids.
  • the low refractive index layer preferably contains 5 to 80% by mass of polymer.
  • the polymer has a function of adhering fine particles and maintaining the structure of a low refractive index layer including voids.
  • the amount of the polymer used is adjusted so that the strength of the low refractive index layer can be maintained without filling the voids.
  • the amount of the polymer is preferably 10 to 30% by mass with respect to the total amount of the low refractive index layer.
  • (1) the polymer is bonded to the surface treatment agent of the fine particles, (2) the fine particles are used as a core, and a polymer shell is formed around the fine particles. It is preferable to use a polymer as the binder.
  • the polymer to be bonded to the surface treatment agent (1) is preferably the shell polymer (2) or the binder polymer (3).
  • the polymer (2) is preferably formed around the fine particles by a polymerization reaction before preparing the coating solution for the low refractive index layer.
  • the polymer (3) is preferably formed by adding a monomer to the coating solution for the low refractive index layer and performing a polymerization reaction simultaneously with or after the coating of the low refractive index layer. It is preferable to carry out a combination of two or all of the above (1) to (3), and to carry out a combination of (1) and (3) or a combination of (1) to (3). Particularly preferred.
  • (1) Surface treatment, (2) shell, and (3) binder will be described sequentially.
  • the fine particles are subjected to a surface treatment to improve the affinity with the polymer.
  • the surface treatment can be classified into physical surface treatment such as plasma discharge treatment and corona discharge treatment, and chemical surface treatment using a coupling agent. It is preferable to carry out only chemical surface treatment or a combination of physical surface treatment and chemical surface treatment.
  • an organoalkoxy metal compound eg, titanium coupling agent, silane coupling agent
  • the fine particles are made of silicon dioxide, surface treatment with a silane coupling agent can be carried out particularly effectively.
  • silane coupling agent examples include methyltrimethoxysilane, methyltriethoxysilane, methyltrimethoxyethoxysilane, methyltriacetoxysilane, methyltributoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, vinyltriethoxysilane.
  • silane coupling agents having a disubstituted alkyl group with respect to silicon include dimethyldimethoxysilane, phenylmethyldimethoxysilane, dimethyldiethoxysilane, phenylmethyldiethoxysilane, and ⁇ -glycidyloxypropylmethyldiethoxysilane.
  • ⁇ -acryloyloxypropylmethyldimethoxysilane, ⁇ -acryloyloxypropylmethyldiethoxysilane, ⁇ -methacryloyloxypropylmethyldimethoxysilane, ⁇ -methacryloyloxypropylmethyldiethoxy are those having a disubstituted alkyl group with respect to silicon.
  • Silane, methylvinyldimethoxysilane and methylvinyldiethoxysilane are preferred, ⁇ -acryloyloxypropyltrimethoxysilane and ⁇ -methacryloyloxy Particularly preferred are propyltrimethoxysilane, ⁇ -acryloyloxypropylmethyldimethoxysilane, ⁇ -acryloyloxypropylmethyldiethoxysilane, ⁇ -methacryloyloxypropylmethyldimethoxysilane and ⁇ -methacryloyloxypropylmethyldiethoxysilane.
  • silane coupling agents Two or more coupling agents may be used in combination.
  • other silane couplings may be used.
  • Other silane coupling agents include alkyl esters of orthosilicate (eg, methyl orthosilicate, ethyl orthosilicate, n-propyl orthosilicate, i-propyl orthosilicate, n-butyl orthosilicate, sec-butyl orthosilicate, orthosilicate). Acid t-butyl) and hydrolysates thereof.
  • the surface treatment with the coupling agent can be carried out by adding the coupling agent to the dispersion of fine particles and leaving the dispersion at a temperature from room temperature to 60 ° C. for several hours to 10 days.
  • inorganic acids for example, sulfuric acid, hydrochloric acid, nitric acid, chromic acid, hypochlorous acid, boric acid, orthosilicic acid, phosphoric acid, carbonic acid
  • organic acids for example, acetic acid, polyacrylic acid, Benzenesulfonic acid, phenol, polyglutamic acid
  • salts thereof eg, metal salts, ammonium salts
  • the polymer forming the shell is preferably a polymer having a saturated hydrocarbon as the main chain.
  • a polymer containing a fluorine atom in the main chain or side chain is preferred, and a polymer containing a fluorine atom in the side chain is more preferred.
  • Polyacrylic acid esters or polymethacrylic acid esters are preferred, and esters of fluorine-substituted alcohols with polyacrylic acid or polymethacrylic acid are most preferred.
  • the refractive index of the shell polymer decreases as the content of fluorine atoms in the polymer increases.
  • the shell polymer preferably contains 35 to 80% by mass of fluorine atoms, and more preferably contains 45 to 75% by mass of fluorine atoms.
  • the polymer containing a fluorine atom is preferably synthesized by a polymerization reaction of an ethylenically unsaturated monomer containing a fluorine atom.
  • ethylenically unsaturated monomers containing fluorine atoms include fluoroolefins (eg, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoropropylene, perfluoro-2,2-dimethyl-1,3-dioxole), Mention may be made of esters of fluorinated vinyl ethers and fluorine-substituted alcohols with acrylic acid or methacrylic acid.
  • fluoroolefins eg, fluoroethylene, vinylidene fluoride, tetrafluoroethylene, hexafluoropropylene, perfluoro-2,2-dimethyl-1,3-dioxole
  • the polymer forming the shell may be a copolymer comprising a repeating unit containing a fluorine atom and a repeating unit not containing a fluorine atom.
  • the repeating unit containing no fluorine atom is preferably obtained by a polymerization reaction of an ethylenically unsaturated monomer containing no fluorine atom.
  • ethylenically unsaturated monomers that do not contain fluorine atoms include olefins (eg, ethylene, propylene, isoprene, vinyl chloride, vinylidene chloride), acrylic esters (eg, methyl acrylate, ethyl acrylate, 2-acrylic acid 2- Ethyl hexyl), methacrylic acid esters (for example, methyl methacrylate, ethyl methacrylate, butyl methacrylate, ethylene glycol dimethacrylate), styrene and its derivatives (for example, styrene, divinylbenzene, vinyl toluene, ⁇ -methyl styrene), vinyl ether ( For example, methyl vinyl ether), vinyl esters (for example, vinyl acetate, vinyl propionate, vinyl cinnamate), acrylamide (for example, N-tertbutylacrylamide, N-cyclohexylacrylic) Amides
  • a crosslinkable functional group may be introduced into the shell polymer to chemically bond the shell polymer and the binder polymer by crosslinking.
  • the shell polymer may have crystallinity.
  • Tg glass transition temperature
  • the core-shell fine particles preferably contain 5 to 90% by volume, more preferably 15 to 80% by volume of a core composed of inorganic fine particles. Two or more kinds of core-shell fine particles may be used in combination. Further, inorganic fine particles having no shell and core-shell particles may be used in combination.
  • the binder binder polymer is preferably a polymer having a saturated hydrocarbon or polyether as the main chain, and more preferably a polymer having a saturated hydrocarbon as the main chain.
  • the binder polymer is preferably crosslinked.
  • the polymer having a saturated hydrocarbon as the main chain is preferably obtained by a polymerization reaction of an ethylenically unsaturated monomer. In order to obtain a crosslinked binder polymer, it is preferable to use a monomer having two or more ethylenically unsaturated groups.
  • Examples of monomers having two or more ethylenically unsaturated groups include esters of polyhydric alcohols and (meth) acrylic acid (eg, ethylene glycol di (meth) acrylate, 1,4-dichlorohexane diacrylate, pentaerythritol).
  • esters of polyhydric alcohols and (meth) acrylic acid eg, ethylene glycol di (meth) acrylate, 1,4-dichlorohexane diacrylate, pentaerythritol.
  • a crosslinked structure may be introduced into the binder polymer by a reaction of a crosslinkable group.
  • crosslinkable functional groups include isocyanate groups, epoxy groups, aziridine groups, oxazoline groups, aldehyde groups, carbonyl groups, hydrazine groups, carboxyl groups, methylol groups, and active methylene groups.
  • Vinylsulfonic acid, acid anhydride, cyanoacrylate derivative, melamine, etherified methylol, ester and urethane can also be used as a monomer for introducing a crosslinked structure.
  • a functional group that exhibits crosslinkability as a result of the decomposition reaction such as a block isocyanate group, may be used.
  • the cross-linking group is not limited to the above compound, and may be one that exhibits reactivity as a result of decomposition of the functional group.
  • the polymerization initiator used for the polymerization reaction and the crosslinking reaction of the binder polymer is a thermal polymerization initiator or a photopolymerization initiator, and the photopolymerization initiator is more preferable.
  • photopolymerization initiators include acetophenones, benzoins, benzophenones, phosphine oxides, ketals, anthraquinones, thioxanthones, azo compounds, peroxides, 2,3-dialkyldione compounds, disulfide compounds , Fluoroamine compounds and aromatic sulfoniums.
  • acetophenones examples include 2,2-diethoxyacetophenone, p-dimethylacetophenone, 1-hydroxydimethylphenyl ketone, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-4-methylthio-2-morpholinopropiophenone and 2 -Benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone.
  • benzoins include benzoin methyl ether, benzoin ethyl ether, and benzoin isopropyl ether.
  • benzophenones include benzophenone, 2,4-dichlorobenzophenone, 4,4-dichlorobenzophenone and p-chlorobenzophenone.
  • phosphine oxides include 2,4,6-trimethylbenzoyldiphenylphosphine oxide.
  • the binder polymer is preferably formed by adding a monomer to the coating solution for the low refractive index layer, and at the same time as or after coating the low refractive index layer, by a polymerization reaction (further crosslinking reaction if necessary). Even if a small amount of polymer (for example, polyvinyl alcohol, polyoxyethylene, polymethyl methacrylate, polymethyl acrylate, diacetyl cellulose, triacetyl cellulose, nitrocellulose, polyester, alkyd resin) is added to the coating solution for the low refractive index layer Good.
  • a polymer for example, polyvinyl alcohol, polyoxyethylene, polymethyl methacrylate, polymethyl acrylate, diacetyl cellulose, triacetyl cellulose, nitrocellulose, polyester, alkyd resin
  • each layer of the optical film or the coating solution thereof includes a polymerization inhibitor, a leveling agent, a thickener, a coloring inhibitor, an ultraviolet ray Absorbers, silane coupling agents, antistatic agents and adhesion promoters may be added.
  • a polymerization inhibitor for the method of simultaneous application, US Pat. Nos. 2,761,791, 2,941,898, 3,508,947, 3,526,528 and Yuji Harasaki, Coating Engineering, page 253, It is described in Asakura Shoten (1973).
  • a generally used one may be used, and there are a constant torque method, a constant tension method, a taper tension method, a program tension control method with a constant internal stress, etc., and these may be used properly.
  • the winding length of the present invention refers to the length of the optical film that has been wound into a roll after being embossed.
  • the winding length of the optical film is preferably 500 to 8000 m.
  • the winding length of the optical film is less than 500 m, the number of windings of the obtained optical film is too large, and it is difficult to cope with packaging, which is not preferable.
  • the winding length of the optical film exceeds 8000 m, blocking or the like increases, which is not preferable.
  • Examples 1 to 13, Comparative Examples 1 and 2 A cellulose ester film having a length of 3900 m, a width of 1.4 m, and a film thickness of 40 ⁇ m was produced as follows. A back coat layer was provided on one side of the base film, a hard coat layer was provided on the side opposite to the back coat layer, and the following antireflection layer was then applied. Thereafter, an embossed portion as shown below was provided. From the formation of the substrate film to the formation of the antireflection layer, the film was not wound up, but continuously, and wound into a roll after forming the embossed portion. At this time, the base film had a melting point of 300 ° C. and a glass transition temperature of 107 ° C.
  • the prepared dope A was cast on a stainless steel belt.
  • the solvent was evaporated on the stainless steel belt, and the web was peeled off from the stainless steel belt.
  • the peeled web was introduced into a tenter dryer, both ends were gripped with clips and dried at 80 ° C. while being stretched 1.1 times in the width direction, and placed in a roll dryer having respective drying zones of 110 ° C. and then 125 ° C. Drying was terminated while being conveyed through a number of arranged rolls, and a cellulose ester film was prepared.
  • the following backcoat layer coating composition was die-coated so as to have a wet film thickness of 13 ⁇ m, and dried at a drying temperature of 90 ° C. to coat a backcoat layer.
  • ⁇ Backcoat layer coating composition Acetone 30 parts by weight Ethyl acetate 45 parts by weight Isopropyl alcohol 10 parts by weight Diacetyl cellulose 0.5 parts by weight Ultrafine silica 2% acetone dispersion (Aerosil 200V, manufactured by Nippon Aerosil Co., Ltd.) 0.2 parts by weight
  • the following hard coat layer coating composition is die coated on the surface opposite to the back coat layer, dried at 80 ° C. for 5 minutes, and then irradiated with 160 mJ / cm 2 of ultraviolet rays, and the total dry film thickness with the following antireflection layer was provided with a hard coat layer so as to be 5 ⁇ m, and a hard coat film was prepared.
  • ⁇ Hard coat layer coating composition Dipentaerythritol hexaacrylate 70 parts by weight Trimethylolpropane triacrylate 30 parts by weight Photoinitiator (Irgacure 184 (manufactured by Ciba Japan)) 4 parts by weight Ethyl acetate 150 parts by weight Propylene glycol monomethyl ether 150 parts by weight Silicon compound (BYK-307 (manufactured by Big Chemie Japan)) 0.4 parts by mass When the pencil hardness of the hard coat layer was measured, it showed a hardness of 3H and an abrasion resistance effect.
  • the following coating solution for a high refractive index layer is applied using a bar coater, dried at 60 ° C., then irradiated with ultraviolet rays to cure the coating layer, and a high refractive index layer (refractive index 1). .9) was formed. Furthermore, the following coating solution for a low refractive index layer was applied using a bar coater, dried at 60 ° C., then irradiated with ultraviolet rays to cure the coating layer, and the low refractive index layer (refractive index 1.45). ) To form an optical film.
  • the ratio of the above titanium dioxide dispersion and the titanium dioxide dispersion of a mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate (DPHA, Nippon Kayaku Co., Ltd.) is increased, and the refractive index of the high refractive index layer is increased.
  • the amount was adjusted so as to be a ratio, and the mixture was stirred at room temperature for 30 minutes, and then filtered through a polypropylene filter having a pore size of 0.4 ⁇ m to prepare a coating solution for a high refractive index layer.
  • this coating liquid was applied to a cellulose ester film and dried, and the refractive index after UV curing was measured, a high refractive index layer having a refractive index of 1.9 and a dry film thickness of 68 nm was obtained.
  • Preparation of coating solution for low refractive index layer 200 g of a methanol dispersion of silica fine particles having an average particle size of 15 nm (methanol silica sol, manufactured by Nissan Chemical Co., Ltd.), 3 g of a silane coupling agent (KBM-503, manufactured by Shin-Etsu Silicone Co., Ltd.) and 2 g of 0.1 mol / L hydrochloric acid
  • the mixture was stirred at room temperature for 5 hours and then allowed to stand at room temperature for 3 days to prepare a dispersion of silica fine particles treated with silane coupling.
  • An embossing roll with irregularities formed on the surface is heated and pressed against the optical film in which the hard coat layer / antireflection layer is coated on the cellulose ester film, and the width of the embossed film is 20 mm wide at both ends in the width direction of the optical film.
  • An embossed part of 10 ⁇ m was prepared under the following conditions to obtain optical films of Examples 1 to 12 and Comparative Examples 1 to 4 shown in Table 1.
  • Embossing roll material Carbon steel (S45C), quenching treatment
  • Embossing roll surface layer No processing
  • Embossing roll surface temperature 200-260 ° C.
  • the length of the embossed part is La, and the length of the unembossed part is Lb.
  • Comparative Example 1 in which the surface roughness Ra of the side surface of the marking ring and the surface roughness Ra of the upper surface are smaller than 10 ⁇ m, the elongation percentage of the embossed portion is increased and the black band is also generated. This caused quality problems.
  • Comparative Example 2 is an example in which embossing was produced at a conventional low film-forming speed (60 n / min). In this case, since the film forming speed is low, even when the surface roughness Ra of the side surface of the marking ring is 10 ⁇ m or more and the surface roughness Ra of the upper surface is 10 ⁇ m or more, the elongation rate of the embossed part and the black band There was no problem.
  • the method for producing an optical film according to the present embodiment uses an embossing apparatus having an embossing roll having an engraved ring and an embossing back roll, and presses the embossing roll against a long film serving as a base material.
  • the surface roughness Ra of the side surface of the marking ring is in the range of 10 to 20 ⁇ m even though the film forming speed is high.
  • the surface roughness Ra of the upper surface of the marking ring is preferably 10 to 20 ⁇ m.
  • polishing on the upper surface of the marking ring also increases the friction with the base film resin on the upper surface in addition to the side surface of the marking ring described above. It is possible to obtain an optical film in which no occurrence occurs.
  • the side surface and the upper surface of the marking ring are polished using two or more selected from a wire brush, a blast treatment, and a vertical polishing machine.
  • polishing by using a blast processing apparatus, it is possible to perform polishing processing of minute uneven portions.
  • Blasting can be applied to workpieces made of inorganic materials such as metals, glass and ceramics, synthetic resins such as plastics, other resins, wood, rocks, and other various materials, and with compressed fluid
  • inorganic materials such as metals, glass and ceramics, synthetic resins such as plastics, other resins, wood, rocks, and other various materials
  • compressed fluid By spraying at a constant angle and speed, optimum polishing is possible even when the processed surface has a deformed portion.
  • a desired surface roughness can be more effectively imparted to the surface composed of the side surface and the upper surface of the marking ring, and according to the embossing device provided with this marking ring, the end portion An optical film in which no elongation occurs can be obtained.
  • the surface temperature of the embossed back roll is preferably 10 to 50 ° C. or less.
  • the temperature of the embossing roll provided in the embossing device to a low temperature, the heat transfer from the embossing ring surface can be suppressed, and the end elongation of the optical film can be suppressed.
  • the width of the rib shape of the optical film manufactured using the embossing apparatus is 3 to 100 ⁇ m.
  • the friction with the base film resin is increased by using the method of the optical film of the present invention manufactured by using an embossing apparatus having an engraved ring having a surface roughness Ra of 10 to 20 ⁇ m, embossing When the embossing ring pushes in the base film in the step of performing, no end elongation occurs and no black band in a roll shape occurs.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Polarising Elements (AREA)

Abstract

La présente invention concerne un procédé qui est destiné à produire un film optique et dans lequel, dans une étape pour effectuer un gaufrage, lorsqu'un anneau de gaufrage presse un film de substrat, l'étirage de bord de la section gaufrée ne survient pas, et des bandes noires et un blocage ne surviennent pas lorsque le film est sous forme de rouleau. À savoir, le procédé pour produire un film optique produit en utilisant un dispositif de gaufrage, qui est pourvu d'un rouleau postérieur de gaufrage et un rouleau de gaufrage ayant un anneau d'impression, pour presser le rouleau de gaufrage sur un film allongé qui est le substrat, et après avoir effectué le gaufrage, l'enroulement du film, est caractérisé en ce que la vitesse de production de film est d'au moins 80 m/minute et la rugosité de surface (Ra) de la surface latérale de l'anneau d'impression est de 10 à 20 μm.
PCT/JP2012/000893 2011-02-09 2012-02-09 Procédé pour produire un film optique WO2012108209A1 (fr)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014115473A (ja) * 2012-12-10 2014-06-26 Konica Minolta Inc 光学フィルムのロール体とその製造方法、包装体、偏光板および液晶表示装置
JP2014218016A (ja) * 2013-05-08 2014-11-20 富士フイルム株式会社 ナーリング装置及び方法並びにフィルムロール製造方法
WO2017141781A1 (fr) * 2016-02-15 2017-08-24 シャープ株式会社 Élément optique et composition de polymère acrylique
WO2018071936A1 (fr) * 2016-10-19 2018-04-26 Teufelberger Ges.M.B.H. Feuillard de cerclage en plastique et procédé de fabrication de feuillards de cerclage en plastique

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JP2006240228A (ja) * 2005-03-07 2006-09-14 Konica Minolta Opto Inc 光学フィルム、及びその製造方法
JP2009073154A (ja) * 2007-09-25 2009-04-09 Konica Minolta Opto Inc 光学フィルム、及びその製造方法
JP2009208358A (ja) * 2008-03-04 2009-09-17 Konica Minolta Opto Inc 光学フィルム
JP2010269506A (ja) * 2009-05-21 2010-12-02 Bridgestone Corp 積層体形成用エチレン−不飽和エステル共重合体フィルムの製造方法
JP2010274615A (ja) * 2009-06-01 2010-12-09 Konica Minolta Opto Inc 光学フィルムの製造方法、光学フィルム、偏光板及び液晶表示装置

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US8110128B2 (en) * 2005-09-21 2012-02-07 Konica Minolta Opto, Inc. Method of manufacturing an anti-glare anti-reflection film

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JP2006240228A (ja) * 2005-03-07 2006-09-14 Konica Minolta Opto Inc 光学フィルム、及びその製造方法
JP2009073154A (ja) * 2007-09-25 2009-04-09 Konica Minolta Opto Inc 光学フィルム、及びその製造方法
JP2009208358A (ja) * 2008-03-04 2009-09-17 Konica Minolta Opto Inc 光学フィルム
JP2010269506A (ja) * 2009-05-21 2010-12-02 Bridgestone Corp 積層体形成用エチレン−不飽和エステル共重合体フィルムの製造方法
JP2010274615A (ja) * 2009-06-01 2010-12-09 Konica Minolta Opto Inc 光学フィルムの製造方法、光学フィルム、偏光板及び液晶表示装置

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014115473A (ja) * 2012-12-10 2014-06-26 Konica Minolta Inc 光学フィルムのロール体とその製造方法、包装体、偏光板および液晶表示装置
JP2014218016A (ja) * 2013-05-08 2014-11-20 富士フイルム株式会社 ナーリング装置及び方法並びにフィルムロール製造方法
WO2017141781A1 (fr) * 2016-02-15 2017-08-24 シャープ株式会社 Élément optique et composition de polymère acrylique
JPWO2017141781A1 (ja) * 2016-02-15 2018-09-20 シャープ株式会社 光学部材、及び、アクリル系重合性組成物
WO2018071936A1 (fr) * 2016-10-19 2018-04-26 Teufelberger Ges.M.B.H. Feuillard de cerclage en plastique et procédé de fabrication de feuillards de cerclage en plastique

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