WO2012133339A1 - 反射防止フィルム及び偏光板 - Google Patents
反射防止フィルム及び偏光板 Download PDFInfo
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- WO2012133339A1 WO2012133339A1 PCT/JP2012/057792 JP2012057792W WO2012133339A1 WO 2012133339 A1 WO2012133339 A1 WO 2012133339A1 JP 2012057792 W JP2012057792 W JP 2012057792W WO 2012133339 A1 WO2012133339 A1 WO 2012133339A1
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- hard coat
- antireflection film
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- 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
-
- 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
- G02B1/111—Anti-reflection coatings using layers comprising organic materials
-
- 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
- G02B1/113—Anti-reflection coatings using inorganic layer materials only
- G02B1/115—Multilayers
- G02B1/116—Multilayers including electrically conducting layers
-
- 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
- G02B1/14—Protective coatings, e.g. hard coatings
-
- 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
- G02B1/16—Optical coatings produced by application to, or surface treatment of, optical elements having an anti-static effect, e.g. electrically conducting coatings
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
Definitions
- the present invention relates to an antireflection film having excellent hard coat properties, antistatic properties, transparency, and scratch resistance and excellent alkali resistance, a polarizing plate using the antireflection film, and a transmissive liquid crystal display device.
- a display is used in an environment where external light or the like is incident, whether indoors or outdoors. Incident light such as external light is specularly reflected on the display surface and the like, and the reflected image thereby mixes with the display image, thereby degrading the screen display quality. For this reason, it is essential to provide an antireflection function to the display surface and the like, and this antireflection function is required to have higher performance and to be combined with other antireflection functions.
- the antireflection function has a multilayer structure on a transparent substrate, specifically, an antireflection function having a repeating structure of a high refractive index layer and a low refractive index layer each made of a transparent material such as a metal oxide. Obtained by forming a layer.
- These antireflection layers having a multilayer structure can be formed by a dry coating method such as a chemical vapor deposition (CVD) method or a physical vapor deposition (PVD) method.
- CVD chemical vapor deposition
- PVD physical vapor deposition
- These antireflection layers may be formed on a transparent substrate having a relatively flexible surface.
- a method is generally used in which a hard coat layer made of a polymer of an acrylic polyfunctional compound is provided and an antireflection layer is formed thereon.
- This hard coat layer has high surface hardness, gloss, transparency and scratch resistance due to the properties of the acrylic resin.
- it since it has high insulating properties, it is easy to be charged, and there are problems such as dirt due to adhesion of dust etc. to the surface of the product provided with a hard coat layer, and troubles caused by charging in the display manufacturing process.
- an antireflection film comprising an antireflection layer and a hard coat layer on a transparent substrate
- a method for imparting an antistatic function to the hard coat layer, or between the transparent substrate and the hard coat layer or antireflection A method of further providing an antistatic layer between the layer and the hard coat layer has been proposed.
- the antireflection film is used for various image display devices such as a liquid crystal display device (LCD), a plasma display panel (PDP), an electroluminescence display (OLED), and a cathode ray tube (CRT) display device.
- LCDs with an antireflection film are increasing as the screen is enlarged.
- the polarizing plate is indispensable as an optical material.
- a polarizing plate has a structure in which a polarizing layer is protected by two protective films. By imparting an antireflection function to these protective films, significant cost reduction and thinning of the display device can be achieved.
- the protective film is required to have sufficient adhesion with the polarizing layer when bonded to the polarizing layer.
- the adhesion between the protective film and the polarizing layer can be improved by subjecting the surface of the protective film to a saponification treatment to make it hydrophilic.
- the cost for the saponification treatment can be reduced by carrying out the saponification treatment after forming the antireflection layer and / or the antiglare layer on the protective film.
- the vicinity of the surface of the protective film is hydrolyzed by the alkaline solution. Therefore, when the surface of the protective film is saponified after forming the antireflection layer, the adhesion between the protective film and the antireflection layer formed on the hard coat layer is deteriorated or the antireflection performance is changed. There is.
- An object of the present invention is to provide an antireflection film having a high surface hardness and excellent antistatic properties, transparency, scratch resistance and alkali resistance.
- the inventor of the present invention provides an antireflective film comprising a hard coat layer containing a quaternary ammonium salt material and a low refractive index layer provided on the hard coat layer. It has been found that there is a correlation with the hardness, specifically, the microindentation hardness obtained when the indenter indentation depth is 100 nm. And based on this knowledge, it came to the invention which concerns on the following 1st and 2nd side surfaces.
- the first aspect of the present invention comprises a transparent substrate, a first layer, and a second layer having a refractive index lower than that of the first layer in this order.
- One layer relates to an antireflection film obtained by curing a coating film containing an ionizing radiation curable material, a quaternary ammonium salt material, and a leveling material.
- the leveling material may be a fluorine leveling material.
- the amount of the leveling material may be in the range of 0.05 to 5.0 parts by mass in a total of 100 parts by mass of the ionizing radiation curable material, the quaternary ammonium salt material, and the leveling material.
- the surface of the first layer before the formation of the second layer may have a microindentation hardness of 0.45 GPa to 1.0 GPa obtained with an indenter indentation depth of 100 nm.
- the antireflection film has (1) a center line average roughness Ra of the surface of the first layer in the range of 0.001 ⁇ m to 0.010 ⁇ m, and (2) an average of irregularities on the surface of the hard coat layer. You may satisfy
- the second aspect of the present invention is an antireflection film obtained by laminating a transparent substrate, a first layer, and a second layer having a refractive index lower than that of the first layer in this order.
- the first coating film is formed by applying a coating liquid containing an ionizing radiation curable material, a quaternary ammonium salt material, and a leveling material to at least one main surface of the transparent substrate.
- the present invention relates to a method for producing an antireflection film including an application step and a step of irradiating the first coating film with ionizing radiation to obtain the first layer as a cured product of the first coating film.
- the first coating film may be irradiated with the ionizing radiation in an atmosphere having an oxygen concentration of 1% by volume or less.
- the ionizing radiation may be ultraviolet light.
- the present invention relates to a polarizing plate comprising a transparent base material sandwiched and facing the antireflection film.
- FIG. 1 is a schematic cross-sectional view of an antireflection film according to an embodiment.
- FIG. 2 is a schematic cross-sectional view of a polarizing plate provided with an antireflection film according to an embodiment.
- FIG. 3 is a schematic cross-sectional view of a transmissive display device including a polarizing plate according to an embodiment.
- FIG. 1 is a schematic cross-sectional view of an antireflection film according to one embodiment.
- the antireflection film 1 includes a transparent substrate 11, a hard coat layer 12, and a low refractive index layer 13.
- the hard coat layer 12 and the low refractive index layer 13 are installed on at least one main surface of the transparent substrate 11.
- the hard coat layer 12 and the low refractive index layer 13 are laminated in this order from the transparent substrate 11 side.
- the refractive index of the low refractive index layer 13 is lower than the refractive index of the uneven distribution layer 12.
- the refractive index of the low refractive index layer 13 is, for example, 0.05 to 0.30 lower than the refractive index of the uneven distribution layer 12.
- the refractive index is, for example, a refractive index measured at a wavelength of 589 nm.
- the hard coat layer 12 and the low refractive index layer 13 will be described below.
- the hard coat layer 12 is obtained from an ionizing radiation curable material and a quaternary ammonium salt material.
- the hard coat layer 12 is obtained by curing, for example, by irradiating a hard coat layer forming coating solution containing these materials with ionizing radiation.
- the hard coat layer 12 is formed, for example, by applying the coating liquid to at least one main surface of the transparent substrate and curing the ionizing radiation curable material contained in the coating liquid by ionizing radiation. To do.
- the quaternary ammonium salt material can impart conductivity to the antireflection film and obtain an antireflection film having antistatic properties.
- the film thickness of the hard coat layer 12 is preferably in the range of 5 ⁇ m to 10 ⁇ m. If the thickness of the hard coat layer is 3 ⁇ m or more, the strength is sufficient, but it is preferable from the viewpoint of coating accuracy and handleability to be within the range of 5 ⁇ m to 10 ⁇ m. When the film thickness exceeds 10 ⁇ m, the substrate may be warped, distorted and / or broken due to curing shrinkage.
- the film thickness of the hard coat layer 12 is more preferably in the range of 5 ⁇ m to 7 ⁇ m.
- the low refractive index layer 13 is provided on the hard coat layer 12. No other layer is interposed between the low refractive index layer 13 and the hard coat layer 12. That is, the low refractive index layer 13 is provided directly on the low refractive index layer 13.
- the low refractive index layer 13 is obtained from an ionizing radiation curable material and low refractive index particles.
- the low refractive index layer 13 can be obtained by irradiating a coating liquid for forming a low refractive index layer containing these materials with ionizing radiation and curing it.
- the low refractive index layer 13 is formed, for example, by applying the coating liquid on the hard coat layer and curing the ionizing radiation curable material with ionizing radiation.
- the film thickness (d) of the low refractive index layer 13 is such that the optical film thickness (nd) obtained by multiplying the film thickness (d) by the refractive index (n) of the low refractive index layer is 1 / wavelength of visible light. Designed to be equal to 4.
- the film thickness (d) of the low refractive index layer 13 is in the range of 50 nm to 150 nm, for example.
- the antireflection film 1 may further include a functional layer (not shown).
- the functional layer is provided between the transparent substrate 11 and the hard coat layer 12.
- the functional layer is, for example, an electromagnetic wave shielding layer having electromagnetic wave shielding performance, an infrared absorbing layer having infrared absorption performance, an ultraviolet absorption layer having ultraviolet absorption performance, or a color correction layer having color correction performance.
- the antireflection film has a microindentation hardness obtained in the range of 0.45 GPa to 1.0 GPa with respect to the hardcoat layer surface of the hardcoat layer 12 before the formation of the low refractive index layer, with an indenter indentation depth of 100 nm. It is.
- the microindentation hardness is in such a range, the antireflection film can have sufficient alkali resistance.
- the indentation depth of the hard coat layer surface of the hard coat layer before the formation of the low refractive index layer is 100 nm, and the indentation hardness is 0.45 GPa. That is all you need.
- the microindentation hardness obtained with the indenter indentation depth of 100 nm is within the range of 0.45 GPa to 1.0 GPa on the surface of the hard coat layer before forming the low refractive index layer. It is characterized by being.
- the antireflection film does not have sufficient alkali resistance, and film peeling of the low refractive index layer 13 occurs when the antireflection film is immersed in an alkaline solution. To do.
- the scratch resistance is weakened due to insufficient hardness near the surface of the hard coat layer.
- the microindentation hardness obtained with an indenter indentation depth of 100 nm can be determined using an ultrafine indentation hardness tester.
- the hard coat layer 12 having a microindentation hardness of 0.45 GPa or more can be obtained, for example, by irradiating with ultraviolet rays in an atmosphere having an oxygen concentration of 1% by volume or less when curing an ionizing radiation curable material.
- This atmosphere having an oxygen concentration of 1% by volume or less is achieved by purging the ultraviolet irradiation portion with an inert gas such as nitrogen.
- the antireflection film preferably has a center line average roughness Ra on the surface of the hard coat layer in the range of 0.001 ⁇ m to 0.010 ⁇ m, and an average interval Sm of irregularities on the surface of the hard coat layer. It satisfies at least one of within the range of 0.15 mm to 1.00 mm.
- the surface of the hard coat layer does not have fine irregularities and is as smooth as possible.
- the alkali resistance of the antireflection film can be made sufficient by smoothing the surface of the hard coat layer.
- the centrality average height (Ra) exceeds 0.010 ⁇ m the hard coat layer surface may have fine irregularities, and the anti-reflection film may not have sufficient alkali resistance.
- the center line average roughness (Ra) exceeds 0.10 ⁇ m
- the hard coat layer is assumed to be smooth if the average interval (Sm) of the irregularities is 0.15 mm or more. Can do.
- the antireflection film can be obtained in which the hard coat layer surface has fine irregularities. In some cases, it may not be possible to achieve sufficient alkali resistance.
- the antireflection film has a center line average roughness Ra on the surface of the hard coat layer in the range of 0.001 ⁇ m to 0.010 ⁇ m, or an average interval Sm of irregularities on the surface of the hard coat layer of 0.15 mm to 1. It is preferably within the range of 00 mm.
- the center line average roughness Ra of the hard coat layer surface is in the range of 0.001 ⁇ m to 0.010 ⁇ m, or the average interval Sm of the irregularities on the surface of the hard coat layer is in the range of 0.15 mm to 1.00 mm.
- the hard coat layer forming material is a material obtained by removing the solvent from the hard coat layer forming coating solution, and means the solid content of the hard coat layer forming coating solution.
- the antireflection film according to this embodiment is manufactured as follows, for example.
- a transparent substrate is prepared.
- a cellulose-based film such as a triacetylcellulose film
- a cellulose-based film such as a triacetylcellulose film
- Cellulose-based films have little birefringence, and are excellent in optical properties such as transparency, refractive index, dispersion, and various physical properties such as impact resistance, heat resistance, and durability. It can be suitably used for a liquid crystal display device.
- a cellulose film can also be used suitably.
- Cellulose-based film can be easily dissolved or swollen with a solvent when a coating liquid for forming a hard coat layer is applied on a transparent substrate, so that a hard coat layer is formed on the transparent substrate as described later. It is possible to effectively prevent the occurrence of interference unevenness due to the film thickness of the hard coat layer formed at the time.
- Various stabilizers, ultraviolet absorbers, plasticizers, lubricants, colorants, antioxidants, flame retardants and the like may be added to the transparent substrate.
- the thickness of the transparent substrate is not particularly limited, but is preferably in the range of 20 ⁇ m to 200 ⁇ m.
- the thickness of the transparent substrate is preferably in the range of 40 ⁇ m to 80 ⁇ m.
- a coating liquid for forming a hard coat layer is applied to one main surface of the transparent substrate.
- a hard coat layer forming coating solution is applied to one main surface of the transparent substrate by a wet film forming method.
- wet film forming methods include dip coating, spin coating, flow coating, spray coating, roll coating, gravure roll coating, air doctor coating, blade coating, wire doctor coating, and knife coating. , Reverse coating method, transfer roll coating method, micro gravure coating method, kiss coating method, cast coating method, slot orifice coating method, calendar coating method, and die coating method. Since the hard coat layer 12 is particularly required to be thin and uniformly formed, it is preferable to use a micro gravure coating method as a wet film forming method. When it is necessary to form a thick layer, a die coating method can be used as a wet film forming method.
- the coating film is applied, for example, so that the thickness of the hard coat layer is 3 ⁇ m or more. If the film thickness is 3 ⁇ m or more, sufficient strength is obtained. Moreover, it is preferable that a coating film is apply
- the coating liquid for forming the hard coat layer contains an ionizing radiation curable material and a quaternary ammonium salt material.
- Acrylic material can be used as the ionizing radiation curable material.
- Acrylic materials are synthesized from monofunctional or polyfunctional (meth) acrylate compounds such as polyhydric alcohol acrylic acid or methacrylic acid ester, diisocyanate and polyhydric alcohol, and acrylic acid or methacrylic acid hydroxy ester.
- Such a polyfunctional urethane (meth) acrylate compound can be used.
- polyether resins having an acrylate functional group polyester resins, epoxy resins, alkyd resins, spiroacetal resins, polybutadiene resins, polythiol polyene resins, and the like can be used. .
- (meth) acrylate refers to both “acrylate” and “methacrylate”.
- urethane (meth) acrylate indicates both “urethane acrylate” and “urethane methacrylate”.
- Examples of the monofunctional (meth) acrylate compound include 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 2-hydroxybutyl (meth) acrylate, n-butyl (meth) acrylate, isobutyl ( (Meth) acrylate, t-butyl (meth) acrylate, glycidyl (meth) acrylate, acryloylmorpholine, N-vinylpyrrolidone, tetrahydrofurfuryl acrylate, cyclohexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, isobornyl (meth) ) Acrylate, isodecyl (meth) acrylate, lauryl (meth) acrylate, tridecyl (meth) acrylate, cetyl (meth) acrylate, stearyl (meth) acrylate, benz
- bifunctional (meth) acrylate compound examples include ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, butanediol di (meth) acrylate, hexanediol di (meth) acrylate, and nonanediol di (meth).
- Examples of the tri- or higher functional (meth) acrylate compound include trimethylolpropane tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, propoxylated trimethylolpropane tri (meth) acrylate, and tris 2-hydroxyethyl.
- tri (meth) acrylate such as isocyanurate tri (meth) acrylate and glycerol tri (meth) acrylate
- pentaerythritol tri (meth) acrylate dipentaerythritol tri (meth) acrylate, ditrimethylolpropane tri (meth) acrylate
- Functional (meth) acrylate compounds pentaerythritol tetra (meth) acrylate, ditrimethylolpropane tetra (meth) acrylate, dipentaerythritol tet Trifunctional or more polyfunctional (meta) such as (meth) acrylate, dipentaerythritol penta (meth) acrylate, ditrimethylolpropane penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, ditrimethylolpropane hexa (meth) acrylate
- a polyfunctional urethane acrylate is preferably used because the desired molecular weight and molecular structure can be designed and the physical properties of the formed hard coat layer can be easily balanced. be able to.
- the urethane acrylate is obtained by reacting a polyhydric alcohol, a polyvalent isocyanate, and a hydroxyl group-containing acrylate.
- quaternary ammonium salt material As the quaternary ammonium salt material, a structure of —N + X ⁇ is shown, and by providing a quaternary nitrogen atom (—N + ) and an anion (X ⁇ ), the hard coat layer is made conductive.
- X ⁇ may be Cl ⁇ , Br ⁇ , I ⁇ , F ⁇ , HSO 4 ⁇ , SO 4 2 ⁇ , NO 3 ⁇ , PO 4 3 ⁇ , HPO 4 2 ⁇ , H 2 PO 4 ⁇ , SO 2. 3 -, OH -, and the like can be given.
- an acrylic material containing a quaternary ammonium cation as a functional group in the molecule can be suitably used as the quaternary ammonium salt material.
- the acrylic material containing a quaternary ammonium cation in the molecule as a functional group include polyfunctional or polyfunctional polyfunctional alcohols such as acrylic acid or methacrylic acid ester containing a quaternary ammonium cation in the molecule as a functional group ( A polyfunctional urethane (meth) acrylate compound synthesized from a (meth) acrylate compound, a diisocyanate and a polyhydric alcohol, a hydroxyester of acrylic acid or methacrylic acid, or the like can be used.
- polyether resins having an acrylate functional group polyester resins, epoxy resins, alkyd resins, spiroacetal resins, polybutadiene resins, polythiol polyene resins, and the like can be used. .
- an acrylic material containing a quaternary ammonium cation as a functional group in the molecule specifically, light ester DQ-100 (manufactured by Kyoeisha Chemical Co., Ltd.) or the like can be used.
- a low refractive index layer can be stably formed on the hard coat layer.
- a hard coat layer is formed using a material having a quaternary ammonium cation and not having an acrylic group and / or methacryl group and an acrylic material not having a quaternary ammonium cation, a quaternary ammonium cation is included.
- the material is segregated on the surface, which may cause the low refractive index layer forming coating solution to be repelled when the low refractive index layer forming coating solution is applied onto the hard coat layer.
- the formed low refractive index layer may be whitened.
- An acrylic material containing a quaternary ammonium cation in the molecule can form a matrix and prevent surface segregation.
- An antistatic function can be imparted to the hard coat layer by forming the hard coat layer using a quaternary ammonium salt material. Forming a hard coat layer using a quaternary ammonium salt material among conductive materials to form a hard coat layer having antistatic properties using only a conductive material such as metal particles or metal oxide particles; In comparison, a decrease in the total light transmittance can be prevented, and further, occurrence of interference unevenness can be suppressed.
- the interference unevenness of the antireflection film becomes more prominent as the refractive index difference between the transparent substrate and the hard coat layer increases.
- the hard coat layer is formed using only conductive particles such as metal particles and metal oxide particles
- the scratch resistance on the surface of the antireflection layer is reduced and the adhesion between the hard coat layer and the transparent substrate is reduced. Decline is confirmed.
- the increase in the refractive index of the hard coat layer can be prevented compared to the case where the hard coat layer is formed using only conductive particles such as metal particles and metal oxide particles. And an antireflection film free from interference unevenness can be obtained.
- An acrylic material containing a quaternary ammonium cation in the molecule as a functional group corresponds to both an ionizing radiation curable material and a quaternary ammonium salt material.
- an acrylic material containing a quaternary ammonium cation as a functional group in the molecule is used, an ionizing radiation curable material having no quaternary ammonium cation is added to the coating liquid as necessary.
- the hard coat layer forming coating solution may contain a leveling agent.
- a leveling agent a fluorine-based leveling agent is preferable.
- the fluorine leveling agent for example, a compound having a perfluoroalkyl group or a fluorinated alkenyl group in the main chain or side chain can be used.
- the effect as a leveling material can be further increased.
- the fluorine-based leveling agent include BYK-340 manufactured by BYK Japan, Neoterfactant 222F, DIC F470, Osaka Organic Chemical Industry V-8FM, and the like. It is not limited to these.
- the content of the fluorine leveling agent is preferably in the range of 0.05 to 5.0 parts by mass with respect to 100 parts by mass of the hard coat layer forming material.
- the center line average roughness Ra of the hard coat layer is in the range of 0.001 ⁇ m to 0.010 ⁇ m, or unevenness on the surface of the hard coat layer.
- An antireflection film having an average interval Sm in the range of 0.15 mm to 1.00 mm or less can be obtained.
- the hard coat layer forming coating solution may further contain a solvent.
- the solvent is preferably a solvent that dissolves or swells the surface of the transparent substrate.
- the solvent for dissolving or swelling the cellulose film surface is, for example, dibutyl ether, dimethoxymethane, dimethoxyethane, diethoxyethane, propylene oxide, 1,4-dioxane, 1 , 3-dioxolane, 1,3,5-trioxane, ethers such as tetrahydrofuran, anisole and phenetole, acetone, methyl ethyl ketone, diethyl ketone, dipropyl ketone, diisobutyl ketone, cyclopentanone, cyclohexanone, methylcyclohexanone, and methylcyclohexanone Ketones such as ethyl formate, propyl formate, n-pentyl formate, methyl acetate, ethyl acetate, methyl propionate, propion brewed ethyl,
- dibutyl ether dimethoxyme
- methyl acetate ethyl acetate, methyl ethyl ketone, acetylacetone, acetone, and cyclohexanone.
- a photopolymerization initiator is added to the coating liquid.
- the photopolymerization initiator is preferably added in the range of 0.5 to 10.0 parts by mass with respect to 100 parts by mass of the solid content of the hard coat layer forming coating solution.
- the content of the photopolymerization initiator is less than 0.5 parts by mass with respect to 100 parts by mass of the hard coat layer forming material, when the ionizing radiation curable material is cured by ultraviolet rays, the polymerization reaction becomes insufficient and the resin is cured. Without, the hardness of the hard coat layer is lowered.
- photopolymerization initiator examples include 2,2-ethoxyacetophenone, 1-hydroxycyclohexyl phenyl ketone, dibenzoyl, benzoin, benzoin methyl ether, benzoin ethyl ether, p-chlorobenzophenone, p-methoxybenzophenone, Michler ketone, acetophenone, 2 -Chlorothioxanthone and the like. You may use these individually or in combination of 2 or more types.
- a photosensitizer can be used in combination with the photopolymerization initiator.
- the photosensitizer include tertiary amines such as triethylamine, triethanolamine and 2-dimethylaminoethanol, alkylphosphine series such as triphenylphosphine, and thioether series such as ⁇ -thiodiglycol.
- a photosensitizer can also be used in mixture of 1 type, or 2 or more types of these.
- the hard coat layer forming coating solution may contain an antifoaming agent, an antioxidant, an ultraviolet absorber, a light stabilizer, a polymerization inhibitor and the like for further performance improvement.
- Examples of the method for drying the coating include air drying, hot air drying, heat drying, and combinations thereof.
- ionizing radiation for example, ultraviolet rays and electron beams can be used.
- ultraviolet rays a high pressure mercury lamp, a halogen lamp, a xenon lamp, a fusion lamp, or the like can be used.
- the amount of ultraviolet irradiation is in the range of 100 mJ / cm 2 to 800 mJ / cm 2 .
- the crosslinking reaction or the polymerization reaction of the ionizing radiation curable resin composition is caused in an atmosphere having an oxygen concentration of 0.1% by volume or less.
- the atmosphere having an oxygen concentration of 1% by volume or less is preferably achieved by replacing the atmosphere (nitrogen concentration of about 80% by volume, oxygen concentration of about 20% by volume) with another gas, and particularly preferably, for example, nitrogen gas or the like This is accomplished by replacement with an inert gas (for example, nitrogen purge). In this way, a hard coat layer is formed.
- a functional layer may be provided between the hard coat layer and the transparent substrate film.
- the functional layer is, for example, an electromagnetic wave shielding layer having electromagnetic wave shielding performance, an infrared absorbing layer having infrared absorption performance, an ultraviolet absorption layer having ultraviolet absorption performance, or a color correction layer having color correction performance.
- a low refractive index layer is formed on the hard coat layer.
- the low refractive index layer is generally formed by a wet film forming method or a dry film forming method.
- a coating solution for forming a low refractive index layer is applied to the surface of the hard coat layer to form an antireflection layer.
- an antireflection layer is formed in a vacuum. Examples of the dry film forming method include a vacuum deposition method, a sputtering method, and a CVD method.
- an antireflection film can be produced at low cost by using a wet film-forming method using a low refractive index forming coating liquid containing an ionizing radiation curable material and low refractive index particles.
- a low refractive index layer is formed by a wet film forming method will be described below.
- the low refractive index layer is obtained from a coating solution for forming a low refractive index layer.
- a coating solution is formed by applying a coating solution for forming a low refractive index layer on the hard coat layer by a wet film formation method.
- the wet film formation method the wet film formation method exemplified when applying the coating liquid for forming the hard coat layer can be used.
- the coating solution for forming a low refractive index layer contains an ionizing radiation curable material and low refractive index particles.
- the coating liquid for forming a low refractive index layer has an optical film thickness (nd) obtained by multiplying the film thickness (d) of the low refractive index layer by the refractive index (n) of the low refractive index layer. Is applied to be equal to 1/4 of the wavelength of visible light.
- the acrylic materials exemplified as the ionizing radiation curable material contained in the hard coat layer forming coating liquid can be used.
- Low refractive index particles LiF, MgF, 3NaF.AlF or AlF (all with a refractive index of 1.4), or Na 3 AlF 6 (cryolite, with a refractive index of 1.33) or other low refractive material.
- Low refractive index particles can be used.
- grain can be used suitably.
- the voids can have a refractive index of air ( ⁇ 1). Therefore, it can be set as the low refractive index particle
- porous silica particles or low refractive index silica particles having voids inside can be used.
- the low refractive index particles preferably have a particle size in the range of 1 nm to 100 nm.
- the particle diameter exceeds 100 nm, light is remarkably reflected by Rayleigh scattering, and the low refractive index layer tends to be whitened and the transparency of the antireflection film tends to be lowered.
- the particle size is less than 1 nm, problems such as non-uniformity of particles in the low refractive index layer due to aggregation of particles occur.
- the coating solution for forming a low refractive index layer may contain a solvent and various additives as necessary.
- Solvents include aromatic hydrocarbons such as toluene, xylene, cyclohexane and cyclohexylbenzene, hydrocarbons such as n-hexane, dibutyl ether, dimethoxymethane, dimethoxyethane, diethoxyethane, propylene oxide, dioxane, dioxolane, and trioxane.
- Ethers such as tetrahydrofuran, anisole and phenetole, and ketones such as methyl isobutyl ketone, methyl butyl ketone, acetone, methyl ethyl ketone, diethyl ketone, dipropyl ketone, diisobutyl ketone, cyclopentanone, cyclohexanone, methylcyclohexanone, and methylcyclohexanone , Ethyl formate, propyl formate, n-pentyl formate, methyl acetate, ethyl acetate, methyl propionate, ethyl propionate , Esters such as n-pentyl acetate and ⁇ -ptyrolactone, cellosolves such as methyl cellosolve, cellosolve, butyl cellosolve, cellosolve acetate, alcohols such as methanol, ethanol, isopropyl
- a surface adjusting agent, a leveling agent, a refractive index adjusting agent, an adhesion improver, a photosensitizer, etc. can be added to the coating liquid as additives.
- a photopolymerization initiator is added to the coating liquid.
- the photoinitiator illustrated as a photoinitiator contained in the coating liquid for hard-coat layer formation can be used.
- the prepared coating liquid for forming a low refractive index layer is applied onto the hard coat layer to form a coating film, and the coating film is dried as necessary.
- a drying method the same method as described in the section of the hard coat layer formation can be used.
- the coating film is irradiated with ionizing radiation to obtain a low refractive index layer.
- the ionizing radiation curable material undergoes a curing reaction to form a binder matrix, thereby obtaining a low refractive index layer.
- the ionizing radiation used is, for example, ultraviolet rays and electron beams.
- An antireflection film is obtained as described above.
- FIG. 2 is a schematic cross-sectional view of a polarizing plate according to this embodiment.
- the polarizing plate 2 includes the antireflection film 1 described above.
- the antireflection film 1 includes a substrate 11a, a hard coat layer 12, and a low refractive index layer 13.
- the polarizing plate 2 further includes a substrate 11b. That is, the polarizing plate 2 includes two transparent base materials 11 a and 11 b, a polarizing layer 23, and the substrate 11. In the polarizing plate 2, the polarizing layer 23 is interposed between the transparent substrates 11a and 11b.
- a polarizing layer 23 and a transparent substrate 11b are provided on the surface opposite to the surface on which the low refractive index layer 13 of the transparent substrate 11a is provided.
- the polarizing layer 23 and the second transparent base material 11b are laminated in this order on the transparent base material 11b. That is, in the polarizing plate 2, the two transparent base materials 11 a and 11 b sandwich the polarizing layer 23.
- polarizing layer 23 for example, stretched polyvinyl alcohol (PVA) to which iodine is added can be used.
- PVA stretched polyvinyl alcohol
- the transparent base material 11b the same material as described in the above-mentioned antireflection film can be used.
- a film made of triacetyl cellulose can be suitably used.
- Saponification treatment is performed before the antireflection film 1 and the transparent base material 11 b are bonded to the polarizing layer 23.
- the saponification treatment is performed by immersing the antireflection film 1 and the transparent substrate 11b in an alkaline solution.
- the alkaline solution is, for example, an aqueous sodium hydroxide solution and an aqueous potassium hydroxide solution.
- the antireflection film 1 has alkali resistance, and the antireflection performance does not change even when subjected to such a saponification treatment. That is, it has excellent saponification resistance.
- the antireflection film having no saponification resistance needs to be provided with a protective film on the low refractive index layer during the saponification treatment, but in this embodiment, the protective film is not required. Therefore, an antireflection film and a polarizing plate can be provided at low cost.
- FIG. 3 is a schematic cross-sectional view of the transmissive display device 6.
- the antireflection film 1 is provided on the outermost surface of the transmissive liquid crystal display device 6.
- the outermost surface of the transmissive liquid crystal display device 6 is arranged to be the front surface, that is, the observer side.
- the transmissive display device 6 includes the polarizing plate 2 described above.
- the polarizing plate 2 includes an antireflection film 1, a polarizing layer 23, and a transparent substrate 11b.
- the polarizing layer 23 faces the hard coat layer 12 with the transparent substrate 11a interposed therebetween.
- the transparent base materials 11a and 11b sandwich the polarizing layer 23.
- the transmissive display device 6 further includes a further polarizing plate 4.
- the polarizing plate 4 includes two transparent base materials 41 and 42 and a polarizing layer 43. In the polarizing plate 4, the transparent base materials 41 and 42 sandwich the polarizing layer 23.
- the transmissive display device 6 further includes a liquid crystal cell 3.
- the liquid crystal cell 3 is installed between the polarizing plates 2 and 4.
- one transparent substrate is a TFT substrate provided with a plurality of pixel circuits each including a pixel electrode and a thin film transistor (TFT), and the other transparent substrate has a counter electrode and a color filter. It is the provided color filter substrate.
- a liquid crystal material is sealed between the two substrates.
- the transmissive display device 6 further includes a backlight unit 5.
- the backlight unit 5 includes a light source and a light diffusion plate.
- the backlight unit 5 faces the liquid crystal cell 3 with the polarizing plate 4 interposed therebetween.
- the transmissive liquid crystal display device 6 may further include other functional members.
- Other functional members include, for example, a diffusion film, a prism sheet, a brightness enhancement film for effectively using light emitted from a backlight, and a phase difference film for compensating for a phase difference between a liquid crystal cell and a polarizing plate.
- a diffusion film for example, a diffusion film, a prism sheet, a brightness enhancement film for effectively using light emitted from a backlight, and a phase difference film for compensating for a phase difference between a liquid crystal cell and a polarizing plate.
- a phase difference film for compensating for a phase difference between a liquid crystal cell and a polarizing plate.
- Hardcoat layer forming coating solution 1 Light ester DQ100 (manufactured by Kyoeisha Chemical Co., Ltd.) 10 parts by mass, an acrylic material containing a quaternary ammonium cation, 25 parts by mass of dipentaerythritol triacrylate, 25 parts by mass of pentaerythritol tetraacrylate, 50 parts by mass of urethane acrylate, Irgacure 184 ( 2 parts by mass of Ciba Specialty Chemicals (photopolymerization initiator)) and 0.2 parts by mass of fluorine leveling agent BYK-340 (by Big Chemie) were dissolved in methyl ethyl ketone and applied to form a hard coat layer. 1 was adjusted.
- Hard coat layer forming coating liquid 2 Light ester DQ100 (manufactured by Kyoeisha Chemical Co., Ltd.) 10 parts by mass, an acrylic material containing a quaternary ammonium cation, 25 parts by mass of dipentaerythritol triacrylate, 25 parts by mass of pentaerythritol tetraacrylate, 50 parts by mass of urethane acrylate, Irgacure 184 ( 5 parts by mass of Ciba Specialty Chemicals (photopolymerization initiator) Using 0.5 parts by mass of a fluorine leveling agent BYK-340 (manufactured by Big Chemie), this was dissolved in methyl ethyl ketone to prepare a coating liquid 2 for forming a hard coat layer.
- a fluorine leveling agent BYK-340 manufactured by Big Chemie
- Hard coat layer forming coating solution 4 Light ester DQ100 (manufactured by Kyoeisha Chemical Co., Ltd.) 10 parts by mass, an acrylic material containing a quaternary ammonium cation, 25 parts by mass of dipentaerythritol triacrylate, 25 parts by mass of pentaerythritol tetraacrylate, 50 parts by mass of urethane acrylate, Irgacure 184 ( Using 5 parts by mass of Ciba Specialty Chemicals (photopolymerization initiator), this was dissolved in methyl ethyl ketone to prepare hard coat layer forming coating solution 2.
- Ciba Specialty Chemicals photopolymerization initiator
- Coating liquid 1 for forming a hard coat layer is applied to one side of a triacetylcellulose film (Fuji Film: film thickness 80 ⁇ m), dried in an oven at 80 ° C. for 60 seconds, and after drying, an atmosphere with an oxygen concentration of 0.1% by volume
- a transparent hard coat layer having a dry film thickness of 5 ⁇ m was formed by irradiating ultraviolet rays at an irradiation dose of 200 mJ / m 2 using an ultraviolet irradiation device (Fusion UV System Japan, light source H bulb).
- a coating solution for forming a low refractive index layer was applied on the hard coat layer formed by the above method so that the film thickness after drying was 100 nm.
- a low refractive index layer was formed by irradiating with UV irradiation at an irradiation dose of 200 mJ / m 2 using an ultraviolet irradiation device (Fusion UV System Japan, light source H bulb) to form an antireflection film.
- Example 2 An antireflection film was obtained in the same manner as in Example 1 except that the hard coat layer forming coating solution 2 was used instead of the hard coat layer forming coating solution 1.
- Example 3 An antireflection film was prepared in the same manner as in Example 1 except that the hard coat layer forming coating solution 1 was used and ultraviolet irradiation was performed in the atmosphere (oxygen concentration 20% by volume) when forming the hard coat layer. Obtained.
- haze value was measured according to JIS-K7105-1981 using a image clarity measuring instrument (NDH-2000, manufactured by Nippon Denshoku Industries Co., Ltd.).
- the spectral reflectance at an incident angle of 5 ° was measured using an automatic spectrophotometer (Hitachi, U-4000). Further, the average luminous reflectance was obtained from the obtained spectral reflectance curve. In the measurement, a matte black paint was applied to the surface of the triacetylcellulose film, which is a transparent substrate, on which the low refractive index layer was not formed, and an antireflection treatment was performed.
- the light of the fluorescent lamp was applied to the hard coat layer surface of the film before the low refractive index layer was laminated, and the light diffusion state on the hard coat layer surface was evaluated.
- the case where the light diffusion degree was small and the surface of the hard coat layer was not whitened was rated as ⁇ , and the case where the surface of the hard coat layer was whitened was rated as x.
- the obtained antireflection film was immersed in a 5.0 normal potassium hydroxide aqueous solution, and then the surface state of the antireflection film when the surface was washed with water was visually evaluated.
- a film having no peeling of the coating film (low refractive index layer) on the antireflection film was marked with “ ⁇ ”, and a film with peeling was marked with “X”.
- the antireflection films of ⁇ Example 1> and ⁇ Example 2> were excellent in alkali resistance and scratch resistance. In addition, these antireflection films had antistatic properties and transparency. Furthermore, in these antireflection films, whitening of the hard coat layer surface was suppressed.
- the antireflection film of ⁇ Comparative Example 1> has low scratch resistance. Moreover, generation
- SYMBOLS 1 Antireflection film, 11a, 11b ... Transparent base material, 12 ... Hard-coat layer, 13 ... Low refractive index layer, 2 ... Polarizing plate, 23 ... Polarizing layer, 3 ... Liquid crystal cell, 4 ... Polarizing plate, 41, 42 ... Transparent substrate, 43 ... Polarizing layer, 5 ... Backlight unit, 6 ... Transmission type liquid crystal display device
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Abstract
Description
本発明の一態様に係る反射防止フィルムについて図面を参照して説明する。
本態様に係る反射防止フィルム1は、図1に示すように、透明基材11と、ハードコート層12と、低屈折率層13とを備える。ハードコート層12と低屈折率層13とは、透明基材11の少なくとも一方の主面に設置されている。ハードコート層12と低屈折率層13とは、透明基材11側からこの順で積層されている。低屈折率層13の屈折率は、偏在層12の屈折率と比較して低い。低屈折率層13の屈折率は、例えば、偏在層12の屈折率と比較して、0.05乃至0.30低い。ここで、屈折率は、例えば、波長589nmで測定された屈折率である。
ハードコート層12は、電離放射線硬化型材料と4級アンモニウム塩材料とから得られる。
ハードコート層12は、例えば、これら材料を含んだハードコート層形成塗液に電離放射線を照射することによって硬化して得られる。具体的には、ハードコート層12は、例えば、この塗液を、透明基材の少なくとも一方の主面に塗布し、電離放射線により塗液に含まれる電離放射線硬化型材料を硬化することにより形成する。
図1に示す通り、低屈折率層13は、ハードコート層12上設けられている。
低屈折率層13とハードコート層12の間には、他の層は介在しない。即ち、低屈折率層13の上には、直接、低屈折率層13が設けられている。
本態様に係る反射防止フィルムは、例えば、以下のようにして製造される。
まず、透明基材を用意する。
次に、透明基材の一方の主面に、ハードコート層形成用塗液を塗布する。例えば、透明基材の一方の主面に、湿式成膜法によりハードコート層形成用塗液を塗布する。
電離放射線硬化型材料としては、アクリル系材料を用いることができる。アクリル系材料としては、多価アルコールのアクリル酸またはメタクリル酸エステルのような単官能または多官能の(メタ)アクリレート化合物、ジイソシアネートと多価アルコール及びアクリル酸またはメタクリル酸のヒドロキシエステル等から合成されるような多官能のウレタン(メタ)アクリレート化合物を使用することができる。また、これらの他にも、アクリル系材料として、アクリレート系の官能基を有するポリエーテル樹脂、ポリエステル樹脂、エポキシ樹脂、アルキッド樹脂、スピロアセタール樹脂、ポリブタジエン樹脂、ポリチオールポリエン樹脂等を使用することができる。
4級アンモニウム塩材料としては、-N+X-の構造を示し、四級窒素原子(-N+)とアニオン(X-)とを備えることによりハードコート層に導電性を発現させる。このとき、X-としては、Cl-、Br-、I-、F-、HSO4 -、SO4 2-、NO3 -、PO4 3-、HPO4 2-、H2PO4 -、SO3 -、OH-等を挙げることができる。
次に、透明基材上に形成した塗膜を乾燥する。
続いて、乾燥した塗膜に電離放射線を照射して硬化してハードコート層を得る。
このようにしてハードコート層を形成する。
次に、ハードコート層上に低屈折率層を形成する。
低屈折率層は、低屈折率層形成用塗液から得られる。具体的には、低屈折率層形成用塗液をハードコート層上に湿式成膜法により塗布して塗膜を形成する。湿式成膜法としては、ハードコート層形成用塗液を塗布する際に例示した湿式成膜法を用いることができる。低屈折率層形成用塗液は、電離放射線硬化型材料と低屈折率粒子とを含んでいる。
電離放射線硬化型材料としては、ハードコート層形成用塗液に含まれる電離放射線硬化型材料として例示したアクリル系材料を使用することができる。
低屈折率粒子としては、LiF、MgF、3NaF・AlFまたはAlF(いずれも、屈折率1.4)、または、Na3AlF6(氷晶石、屈折率1.33)等の低屈折材料からなる低屈折率粒子を用いることができる。また、粒子内部に空隙を有する粒子を好適に用いることができる。粒子内部に空隙を有する粒子は、空隙の部分を空気の屈折率(≒1)とすることができる。そのため、非常に低い屈折率を備える低屈折率粒子とすることができる。具体的には、多孔質シリカ粒子や、内部に空隙を有する低屈折率シリカ粒子を用いることができる。
溶媒としては、トルエン、キシレン、シクロヘキサン、シクロヘキシルベンゼンなどの芳香族炭化水素類、n-ヘキサンなどの炭化水素類、ジブチルエーテル、ジメトキシメタン、ジメトキシエタン、ジエトキシエタン、プロピレンオキシド、ジオキサン、ジオキソラン、トリオキサン、テトラヒドロフラン、アニソールおよびフェネトール等のエーテル類、また、メチルイソブチルケトン、メチルブチルケトン、アセトン、メチルエチルケトン、ジエチルケトン、ジプロピルケトン、ジイソブチルケトン、シクロペンタノン、シクロヘキサノン、メチルシクロヘキサノン、およびメチルシクロヘキサノン等のケトン類、また蟻酸エチル、蟻酸プロピル、蟻酸n-ペンチル、酢酸メチル、酢酸エチル、プロピオン酸メチル、プロピオン酸エチル、酢酸n-ペンチル、およびγ-プチロラクトン等のエステル類、さらには、メチルセロソルブ、セロソルブ、ブチルセロソルブ、セロソルブアセテート等のセロソルブ類、メタノール、エタノール、イソプロピルアルコール等のアルコール類、水等の中から塗工適正等を考慮して適宜選択される。また、塗液には添加剤として、表面調整剤、レベリング剤、屈折率調整剤、密着性向上剤、光増感剤等を加えることもできる。
調液された低屈折率層形成用塗液はハードコート層上に塗布され塗膜を形成し、該塗膜に対し、必要に応じて乾燥を行う。乾燥方法としては、上記ハードコート層の形成の項で説明したのと同様の方法を使用することができる。
その後、電離放射線を塗膜に照射して、低屈折率層を得る。電離放射線を照射することにより電離放射線硬化型材料の硬化反応をおこなうことによりバインダマトリックスし、低屈折率層を得る。
以上のようにして、反射防止フィルムを得る。
次に、偏光板について説明する。
図2は、本態様に係る偏光板の断面模式図である。
偏光板2は、上述の反射防止フィルム1を含んでいる。反射防止フィルム1は、基板11a、ハードコート層12及び低屈折率層13を含んでいる。
次に、透過型液晶表示装置について説明する。
図3に示すように、透過型液晶表示装置6において、反射防止フィルム1は、透過型液晶表示装置6の最表面に設けられる。透過型液晶表示装置6が使用される状態において、透過型液晶表示装置6の最表面は、前面、即ち、観察者側となるように配置される。
四級アンモニウムカチオンを含有するアクリル系材料であるライトエステルDQ100(共栄社化学製)10質量部、ジペンタエリスリトールトリアクリレート25質量部、ペンタエリスリトールテトラアクリレート25質量部、ウレタンアクリレート50質量部、イルガキュア184(チバスペシャリティケミカルズ社製(光重合開始剤))2質量部、フッ素系レベリング剤BYK-340(ビックケミー社製)0.2質量部を用い、これをメチルエチルケトンに溶解してハードコート層形成用塗液1を調整した。
四級アンモニウムカチオンを含有するアクリル系材料であるライトエステルDQ100(共栄社化学製)10質量部、ジペンタエリスリトールトリアクリレート25質量部、ペンタエリスリトールテトラアクリレート25質量部、ウレタンアクリレート50質量部、イルガキュア184(チバスペシャリティケミカルズ社製(光重合開始剤))5質量部、
フッ素系レベリング剤BYK-340(ビックケミー社製)0.5質量部を用い、これをメチルエチルケトンに溶解してハードコート層形成用塗液2を調整した。
四級アンモニウムカチオンを含有するアクリル系材料であるライトエステルDQ100(共栄社化学製)10質量部、ジペンタエリスリトールトリアクリレート25質量部、ペンタエリスリトールテトラアクリレート25質量部、ウレタンアクリレート50質量部、イルガキュア184(チバスペシャリティケミカルズ社製(光重合開始剤))20質量部、フッ素系レベリング剤BYK-340(ビックケミー社製)0.5質量部を用い、これをメチルエチルケトンに溶解してハードコート層形成塗液2を調整した。
四級アンモニウムカチオンを含有するアクリル系材料であるライトエステルDQ100(共栄社化学製)10質量部、ジペンタエリスリトールトリアクリレート25質量部、ペンタエリスリトールテトラアクリレート25質量部、ウレタンアクリレート50質量部、イルガキュア184(チバスペシャリティケミカルズ社製(光重合開始剤))5質量部を用い、これをメチルエチルケトンに溶解してハードコート層形成塗液2を調整した。
多孔質シリカ微粒子分散液(平均粒子径50nm、固形分20%、溶剤:メチルイソブチルケトン)14.94質量部、EO変性ジペンタエリスリトールヘキサアクリレート(商品名:DPEA-12、日本化薬製)1.99質量部、重合開始剤(チバ・スペシャリティ・ケミカルズ(株)製、商品名;イルガキュア184)0.07質量部、TSF4460(商品名、GE東芝シリコーン(株)製:アルキルポリエーテル変性シリコーンオイル)0.20質量部を、溶媒であるメチルイソブチルケトン82質量部で希釈して低屈折率層形成用塗液を調整した。
(ハードコート層の形成)
トリアセチルセルロースフィルム(富士フィルム製:膜厚80μm)の片面にハードコート層形成用塗液1を塗布し、80℃・60秒オーブンで乾燥し、乾燥後、酸素濃度0.1体積%の雰囲気下で紫外線照射装置(フュージョンUVシステムジャパン、光源Hバルブ)を用いて照射線量200mJ/m2 で紫外線照射をおこなうことにより乾燥膜厚5μmの透明なハードコート層を形成した。
上記方法にて形成したハードコート層上に低屈折率層形成用塗液を乾燥後の膜厚が100nmとなるように塗布した。紫外線照射装置(フュージョンUVシステムジャパン、光源Hバルブ)を用いて照射線量200mJ/m2 で紫外線照射をおこなって硬化させて低屈折率層を形成し、反射防止フィルムを作製した。
ハードコート層形成用塗液1に代えてハードコート層形成用塗液2を使用したこと以外は実施例1と同様にして、反射防止フィルムを得た。
ハードコート層形成用塗液1に代えてハードコート層形成用塗液3を使用したこと以外は実施例1と同様にして、反射防止フィルムを得た。
ハードコート層形成用塗液1に代えてハードコート層形成用塗液4を使用したこと以外は実施例1と同様にして、反射防止フィルムを得た。
ハードコート層形成用塗液1を使用し、ハードコート層を形成する際に大気下(酸素濃度20体積%)で紫外線照射を行ったこと以外は実施例1と同様にして、反射防止フィルムを得た。
得られた反射防止フィルムについて、写像性測定器(日本電色工業社製、NDH-2000)を使用して、JIS-K7105-1981に準拠して、ヘイズ値を測定した。
得られた反射防止フィルムの低屈折率層表面について、自動分光光度計(日立製作所製、U-4000)を用い、入射角5°における分光反射率を測定した。また、得られた分光反射率曲線から平均視感反射率を求めた。なお、測定の際には透明基材であるトリアセチルセルロースフィルムのうち低屈折率層の形成されていない面につや消し黒色塗料を塗布し、反射防止の処置をおこなった。
得られた反射防止フィルムについて、高抵抗抵抗率計(株式会社ダイアインスツルメンツ社製、ハイレスターMCP-HT260)を使用して、JIS-K6911-1994に準拠して、表面抵抗値を測定した。
スチールウール(#0000)を用い、250g荷重で反射防止フィルムの低屈折率層表面を10往復擦り、傷の有無を目視評価した。傷が確認されなかったものを○、傷が確認されたものを×とした。
低屈折率層を積層する前のフィルムのハードコート層表面に蛍光灯の光を当て、ハードコート層表面の光の拡散具合を評価した。光の拡散具合が小さく、ハードコート層表面が白化していないものを○、ハードコート層表面が白化しているものを×とした。
低屈折率層を積層する前の得られたフィルムのハードコート層表面について、超微小押し込み硬度試験機(MTSシステムズ社製NanoIndenterSA2)を用い、ハードコート層表面について、圧子の押し込み深さを100nmとして得られる微小押し込み硬さを測定した(圧子:先端曲率半径100nm、稜角度80°の三角錐圧子、押し込み速度=2.0nm/s)。
低屈折率層を積層する前の得られたフィルムのハードコート層表面について、高精度微細形状測定器(小坂研究所製サーフコーダーET4000A)を用い、JIS-B0601-1994に準拠して、ハードコート層表面の中心線平均高さ(Ra)を測定した(カットオフ=0.8mm、評価長さ=2.4mm、走査速度=0.2mm/sec)。
低屈折率層を積層する前の得られたハードコートフィルムについて、高精度微細形状測定器(小坂研究所製サーフコーダーET4000A)を用い、JIS-B0601-1994に準拠して、ハードコート層表面凹凸の平均間隔(Sm)を測定した(カットオフ=0.8mm、評価長さ=2.4mm、走査速度=0.2mm/sec)。
得られた反射防止フィルムを5.0規定の水酸化カリウム水溶液に浸漬させ、その後水で表面を洗浄した際の反射防止フィルム表面状態を目視により評価した。反射防止フィルムに塗膜(低屈折率層)の剥れがないものを○、剥れがあるものを×とした。
Claims (9)
- 透明基材と、第1層と、屈折率が前記第1層の屈折率と比較して低い第2層とをこの順で積層してなる反射防止フィルムであって、
前記第1層は、電離放射線硬化型材料と4級アンモニウム塩材料とレベリング材料とを含んだ塗膜を硬化させてなる反射防止フィルム。 - 前記レベリング材料は、フッ素系レベリング材料である請求項1に記載の反射防止フィルム。
- 前記レベリング材料の量は、前記電離放射線硬化型材料と前記4級アンモニウム塩材料と前記レベリング材料との合計100質量部中、0.05乃至5.0質量部の範囲内である請求項1又は2に記載の反射防止フィルム。
- 前記第2層の形成前の第1層の表面について、圧子の押し込み深さを100nmとして得られる微小押し込み硬さが0.45GPa乃至1.0GPaの範囲内である請求項1乃至3のいずれか1項に記載の反射防止フィルム。
- (1)前記第1層の表面の中心線平均粗さRaが0.001μm乃至0.010μmの範囲内であること、及び、
(2)前記ハードコート層表面の凹凸の平均間隔Smが0.15mm乃至1.00mmの範囲内であること
の少なくとも1つの要件を満足する請求項1乃至4のいずれか1項に記載の反射防止フィルム。 - 透明基材と、第1層と、屈折率が前記第1層の屈折率と比較して低い第2層とをこの順で積層してなる反射防止フィルムの製造方法であって、
前記透明基材の少なくとも一方の主面に、電離放射線硬化型材料と4級アンモニウム塩材料とレベリング材料とを含んだ塗液を塗布して第1塗膜を形成する塗布工程と、
前記第1塗膜に電離放射線を照射して、前記第1層を前記第1塗膜の硬化物として得る工程と
を含んだ反射防止フィルムの製造方法。 - 前記第1塗膜に、前記電離放射線を、酸素濃度1体積%以下の雰囲気下で照射する請求項6に記載の製造方法。
- 前記電離放射線は紫外線である請求項6又は7に記載の製造方法。
- 請求項1に記載の反射防止フィルムと、
前記反射防止フィルムの前記透明基材を間に挟んで前記反射防止フィルムの前記第1層と向き合った偏光層と、
前記偏光層を間に挟んで前記反射防止フィルムと向き合った透明基材とを備えた偏光板。
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