WO2014148492A1 - 表面微細凹凸体および表面微細凹凸体の製造方法 - Google Patents

表面微細凹凸体および表面微細凹凸体の製造方法 Download PDF

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Publication number
WO2014148492A1
WO2014148492A1 PCT/JP2014/057345 JP2014057345W WO2014148492A1 WO 2014148492 A1 WO2014148492 A1 WO 2014148492A1 JP 2014057345 W JP2014057345 W JP 2014057345W WO 2014148492 A1 WO2014148492 A1 WO 2014148492A1
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Prior art keywords
resin
fine
fine unevenness
light
sheet
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PCT/JP2014/057345
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English (en)
French (fr)
Japanese (ja)
Inventor
喜久 正田
俊樹 岡安
江梨子 遠藤
Original Assignee
王子ホールディングス株式会社
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Priority to CN201480016299.8A priority Critical patent/CN105143927B/zh
Publication of WO2014148492A1 publication Critical patent/WO2014148492A1/ja

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00—Globes; Bowls; Cover glasses
    • F21V3/04—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings
    • F21V3/049—Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
    • G02B5/0226—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures having particles on the surface
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • G02B5/0205—Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/021—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
    • G02B5/0221—Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures the surface having an irregular structure

Definitions

  • the present invention relates to a light diffusing body and a surface fine concavo-convex body suitably used as a light diffusing body forming original plate and a method for producing the same.
  • the present invention claims priority based on Japanese Patent Application No. 2013-55722 filed in Japan on March 18, 2013 and Japanese Patent Application No. 2014-034687 filed in Japan on February 25, 2014. , The contents of which are incorporated herein.
  • a sheet-like surface fine uneven body on which a concave / convex pattern composed of fine wavy unevenness is formed is used as a light diffuser such as a light diffusing sheet because of its optical characteristics.
  • a method for producing a light diffusive sheet for example, in Patent Document 1, a laminated sheet provided with a resin hard layer on a resin substrate made of a heat shrinkable film is heated to shrink the heat shrinkable film.
  • a method of forming a concavo-convex pattern on the surface of a hard layer by deforming the hard layer so as to be folded into a concavo-convex shape.
  • Patent Document 1 describes that a concavo-convex pattern with small variation in orientation can be formed by stretching after shrinking a heat-shrinkable film.
  • a concavo-convex pattern with small variation in orientation can be formed by stretching after shrinking a heat-shrinkable film.
  • the diffusion angle in the main diffusion direction is large (for example, about 25 to 30 °), and the diffusion angle in the direction orthogonal to the main diffusion direction is small (for example, about 3 °). Excellent anisotropy.
  • a light diffusive sheet having a certain diffusion angle (at least 4 °) in a direction orthogonal to the main diffusion direction while maintaining a wide diffusion angle (at least 18 °) in the main diffusion direction is also required. It is like that.
  • a light diffusing sheet having a certain diffusion angle in a direction perpendicular to the surface is also required.
  • Such a light diffusable sheet is considered to be produced by, for example, using a biaxial heat-shrinkable film that heat-shrinks in the biaxial direction as a heat-shrinkable film and shrinking it in the biaxial direction.
  • a biaxial heat-shrinkable film that heat-shrinks in the biaxial direction as a heat-shrinkable film and shrinking it in the biaxial direction.
  • the present invention has been made in view of the above circumstances, and when used as a light diffuser, also in a direction orthogonal to the main diffusion direction while maintaining a wide diffusion angle (at least 18 °) in the main diffusion direction.
  • a fine surface irregularity body having a certain diffusion angle (at least 4 °) and easy to manufacture, and a method for manufacturing the same.
  • the present invention has the following aspects.
  • a surface fine concavo-convex body having fine irregularities formed on the surface wherein the fine irregularities are: A wavy uneven pattern having a plurality of ridges meandering non-parallel to each other and concave ridges formed between the plurality of ridges, and having a most frequent pitch of 3 to 20 ⁇ m; A fine surface irregularity having a number of hemispherical recesses or hemispherical projections formed on the pattern;
  • ⁇ 2> The fine surface irregularities according to ⁇ 1>, wherein the hemispherical concave portion or the hemispherical convex portion has a mode diameter of 1 to 10 ⁇ m;
  • ⁇ 3> The surface fine unevenness according to ⁇ 1> or ⁇ 2>, wherein the average height of the ridges is 4 to 7 ⁇ m; ⁇ 4> The surface fine unevenness according to any one of ⁇ 1> to ⁇ 3>, wherein an occupied
  • the particles are made of a material whose particle shape is not changed by heat at a temperature lower than the glass transition temperature of the resin constituting the substrate film by 10 ° C., and the particle diameter of the particles is larger than the thickness of the hard layer.
  • Manufacturing method of fine surface irregularities; ⁇ 8> The substrate film is a uniaxial heat-shrinkable film, and the deformation step is a step of heating the laminated sheet to shrink the uniaxial heat-shrinkable film.
  • Method for producing uneven body ⁇ 9> Using the surface fine unevenness produced by the production method according to ⁇ 7> or ⁇ 8> as an original plate for forming a light diffuser, and having a transfer step of transferring the fine unevenness of the surface fine unevenness.
  • a method for producing a light diffuser Using the surface fine unevenness produced by the production method according to ⁇ 7> or ⁇ 8> as an original plate for forming a light diffuser, and having a transfer step of transferring the fine unevenness of the surface fine unevenness.
  • this invention has the following structures.
  • the wavy uneven pattern includes a plurality of irregularly formed ridges and a recess between the plurality of ridges, and the plurality of ridges meander non-parallel to each other.
  • a laminated sheet is formed by providing a hard layer having a thickness of more than 0.05 ⁇ m and less than 5.0 ⁇ m made of matrix resin and particles dispersed in the matrix resin on one side of a base film made of resin.
  • the glass transition temperature of the matrix resin is 10 ° C.
  • the particles are made of a material whose particle shape is not changed by heat at a temperature lower than a temperature 10 ° C. higher than the glass transition temperature of the resin constituting the base film,
  • Manufacturing method of uneven body [8] A transfer step of transferring the fine unevenness of the surface fine unevenness using the surface fine unevenness produced by the production method according to [6] or [7] as a light diffuser forming original plate, A method for producing a light diffuser.
  • a certain diffusion angle (at least 4) in the direction orthogonal to the main diffusion direction while maintaining a wide diffusion angle (at least 18 °) in the main diffusion direction when used as a light diffuser, a certain diffusion angle (at least 4) in the direction orthogonal to the main diffusion direction while maintaining a wide diffusion angle (at least 18 °) in the main diffusion direction. And a method for producing the same can be provided.
  • FIG. 2 is an optical micrograph obtained by observing fine irregularities of the light diffusive sheet of Example 1.
  • FIG. 4 is another laser micrograph of the microscopic unevenness of the light diffusing sheet of Example 1 observed.
  • FIG. 1B is an enlarged longitudinal sectional view schematically showing a portion cut along the line I-I ′ in the optical micrograph of FIG. 1A. It is the Fourier-transform image which acquired the gray scale image from the optical microscope photograph of the light diffusable sheet
  • FIG. 4 is a graph in which a line L1-1 is drawn from the center of FIG.
  • FIG. 4 is a graph in which a line L1-2 is drawn from the center of FIG. 3 in a direction orthogonal to L1-1 and a frequency distribution of the line L1-2 is plotted.
  • It is the longitudinal cross-sectional view of the principal part of the light diffusable sheet
  • FIG. 1A is an optical micrograph (plan view; vertical 0.4 mm ⁇ horizontal) of one side of a light diffusing sheet (light diffusing body) which is an embodiment of the surface fine irregularities of the present invention (Example 1 described later).
  • FIG. 1B is a laser micrograph of the microscopic irregularities of the light diffusing sheet of Example 1 observed with a laser microscope (“VK-8510” manufactured by Keyence Corporation).
  • a line ⁇ in FIG. 1B indicates a height profile of a cut surface obtained by cutting the light diffusing sheet along the line ⁇ in the horizontal direction in the figure. 1A and FIG. 1B have different magnifications.
  • FIG. 1A is an optical micrograph (plan view; vertical 0.4 mm ⁇ horizontal) of one side of a light diffusing sheet (light diffusing body) which is an embodiment of the surface fine irregularities of the present invention (Example 1 described later).
  • FIG. 1B is a laser micrograph of the microscopic irregularities of the light diffusing sheet of Example 1 observed with
  • FIG. 2 is an enlarged vertical cross-sectional view schematically showing a portion cut along a line II ′ (a line along a direction in which a protruding ridge and a recessed ridge described later are repeated) in the optical micrograph of FIG. 1A.
  • FIG. 2 shows a simplified view from the viewpoint of easy understanding of the longitudinal cross-sectional shape of the light diffusive sheet.
  • the “surface fine uneven body” means an article having a fine uneven structure on the surface.
  • the light diffusing sheet 10 of this example includes a transparent base material 11 made of polyethylene terephthalate (PET) and an ionizing radiation curable resin provided on one surface of the base material 11. It has a two-layer structure with a transparent surface layer 12 made of a cured product, and a wavy uneven pattern 13 and a number of protrusions formed on the uneven pattern 13 are formed on the exposed surface of the surface layer 12.
  • corrugation comprised from the part 14 is formed.
  • the convex portion 14 is formed in a substantially hemispherical shape.
  • the exposed surface of the base material 11 (the surface on the side opposite to the side on which the surface layer 12 is provided) is a smooth surface.
  • the wavy uneven pattern 13 in the fine unevenness extends in the vertical direction in FIGS. 1A and 1B, and in FIG. 2, a plurality of streaky protrusions 13a extending in a direction perpendicular to the paper surface, and the plurality of protrusions.
  • the groove portions 13b between the portions 13a are alternately repeated in one direction (lateral direction in FIGS. 1A, 1B and 2).
  • the vertical cross-sectional shape of each ridge 13 a is a tapered shape that becomes thinner from the proximal end side toward the distal end side.
  • each of the plurality of ridge portions 13a meanders, is nonparallel to each other, and is irregularly formed.
  • the ridge line meanders in each protruding line part 13a, and the valley line meanders in each recessed line part 13b. Further, the interval between the ridge lines of the adjacent ridge portions 13a is not constant, and the interval between the valley lines of the adjacent ridge portions 13b is not constant.
  • the irregularity means that when the light diffusion sheet 10 is viewed from the normal direction with respect to the base material, the ridges 13a meander and are not parallel to each other.
  • the ridge line of the part 13a meanders, the valley line of each concave line part 13b meanders, the interval of the ridge line of the adjacent convex line part 13a is not constant, and the interval of the valley line of the adjacent concave line part 13b is Means not constant.
  • the height of the ridge line is not constant in each protruding line part 13a, and the height of the valley line is not fixed in each recessed line part 13b. Therefore, as shown in FIG. 2, the longitudinal cross-sectional shape of each protruding item
  • line part 13a is different, respectively, and is not uniform but irregular.
  • the fine unevenness is composed of such a wave-like uneven pattern 13 and a large number of randomly distributed convex portions 14.
  • the ridgeline of the “ridge 13a” means a line that connects the tops of the ridges 13a.
  • the convex part 14 exists in the middle of the ridgeline of the convex part 13a, it refers to the line drawn so that the top part of the convex part 14 may be passed.
  • a transparent material such as a resin such as polycarbonate, polymethyl methacrylate, polyethylene acrylate, and polystyrene, and glass can be used.
  • the thickness of the substrate 11 is, for example, 30 to 500 ⁇ m.
  • the surface layer 12 include a cured product of a thermosetting resin, a thermoplastic resin, and the like in addition to a cured product of an ionizing radiation curable resin.
  • the ionizing radiation curable resin include an ultraviolet curable resin and an electron beam curable resin.
  • the thickness of the surface layer 12 may be sufficient to form the wavy uneven pattern 13, and the thickness of the thickest portion is preferably about 10 to 25 ⁇ m.
  • the thickness of the surface layer 12 means a thickness before the surface layer 12 is deformed, and can be measured using an optical non-contact film thickness measuring instrument.
  • the fine unevenness of the light diffusing sheet 10 is composed of a wavy uneven pattern 13 and a large number of protrusions 14.
  • the fine unevenness of the surface fine unevenness of the present invention is wavy. You may be comprised from the uneven
  • the repeating direction (the horizontal direction in FIGS. 1A and 1B) of the wavy uneven pattern 13 is referred to as the Y direction
  • the direction orthogonal to the Y direction is referred to as the X direction.
  • the first direction may be referred to as the Y-axis direction
  • the second direction may be referred to as the X-axis direction
  • the direction orthogonal to the XY axis may be referred to as the third direction or the normal direction of the substrate of the surface fine unevenness.
  • the most frequent pitch of the wavy uneven pattern 13 is 3 to 20 ⁇ m from the viewpoint of exhibiting light diffusibility.
  • the most frequent pitch of the wavy uneven pattern 13 is preferably 7 to 15 ⁇ m, more preferably 11 to 13 ⁇ m.
  • the pitch is the distance between the tops of adjacent ridges.
  • a surface on which fine irregularities are formed (hereinafter may be referred to as a fine irregularity forming surface) or a smooth surface side opposite to the surface with respect to the light diffusing sheet 10
  • a sufficient diffusion angle in the Y direction for example, 18 ° or more, preferably 23 °.
  • 1/10 diffusion angle is (diffusion angle ⁇ 1.4 + 25 °) or less, preferably (diffusion angle ⁇ 1.4 + 22 °) or less, more preferably (diffusion angle ⁇ 1.4 + 20).
  • ° Indicates the following.
  • the upper limit value of the diffusion angle in the Y direction is not particularly limited, but is, for example, 30 °.
  • the fine unevenness of the light diffusing sheet 10 in the illustrated example has a large number of randomly formed convex portions 14 in addition to the wavy uneven pattern 13 mainly responsible for diffusion in the main diffusion direction as described above. is doing. Therefore, the anisotropy of the wavy uneven pattern 13 is moderately weakened by the protrusions 14.
  • a certain diffusion angle smaller than the Y direction for example, 4 ° or more, preferably 8 ° or more, more preferably 10 ° or more.
  • 1/10 diffusion angle is (diffusion angle ⁇ 1.6 + 25 °) or less, preferably ( (Diffusion angle ⁇ 1.6 + 20 °) or less, more preferably (Diffusion angle ⁇ 1.6 + 18 °) or less).
  • the upper limit value of the diffusion angle in the X direction is not particularly limited, but is 20 °, for example.
  • the apparent mode diameter of the convex portion 14 is preferably 1 to 10 ⁇ m, more preferably 3 to 6 ⁇ m, still more preferably 4 to 5 ⁇ m. If the apparent mode diameter of the convex portion 14 is within the above range, the anisotropy of the wavy uneven pattern 13 can be moderately weakened, and the diffusion angles in both the Y direction and the X direction are controlled within the above range.
  • the Y direction is preferably controlled at 25 to 30 °
  • the X direction is preferably controlled at 10 to 15 °.
  • the 1/10 diffusion angle in both the Y direction and the X direction can be easily controlled within the above range.
  • the Y direction is preferably (diffusion angle ⁇ 1.4 + 20 °) or less
  • the X direction is preferably (diffusion angle ⁇ 1.6 + 18 °) or less.
  • the diffusion angle in this specification (generally referred to as “FWHM”) and the 1/10 diffusion angle are measured using a light distribution characteristic measurement device (for example, GENESISIA GonioFar Field Profiler (manufactured by Genesia)). It can be measured by the following method.
  • the light diffusing sheet 10 is irradiated with light from one of the surfaces, that is, the fine unevenness forming surface or the opposite smooth surface side.
  • the illuminance curve is obtained by plotting the illuminance value with respect to the light emission angle in each Y direction.
  • the half value width (full half value width) in the illuminance curve is defined as the diffusion angle in the main diffusion direction (Y direction).
  • the 1/10 value width (all 1/10 value widths) is defined as a 1/10 diffusion angle in the main diffusion direction (Y direction).
  • the illuminance of the emitted light within the range of the light emission angle of ⁇ 90 ° to + 90 ° along the X direction is measured every 1 ° as a relative value with respect to the reference value.
  • the illuminance curve is obtained by plotting the illuminance value with respect to the light emission angle in each X direction.
  • the half value width (total half value width) in the illuminance curve is defined as a diffusion angle in a direction (X direction) orthogonal to the main diffusion direction.
  • the 1/10 value width (total 1/10 value width) is defined as a 1/10 diffusion angle in the direction (X direction) orthogonal to the main diffusion direction.
  • the mode pitch of the wavy uneven pattern 13 and the apparent mode diameter of the convex portion 14 are measured and defined as follows.
  • an optical micrograph as shown in FIG. 1A is obtained for the fine surface irregularities.
  • the observation visual field at that time is 0.4 to 1.6 mm in length and 0.5 to 2 mm in width. If this image is a compressed image such as jpeg, it is converted into a grayscale Tif image. Then, Fourier transform is performed to obtain a Fourier transform image as shown in FIG.
  • the schematic diagram of the Fourier-transform image of FIG. 3 is shown as FIG.
  • the white circular ring B in FIG. 3 includes information on the diameters of a large number of convex portions because the shape thereof has no directionality. Therefore, when the line L1-1 is drawn from the center of FIG. 3 so as to pass through the point having the maximum frequency in A1, and the frequency distribution of the line L1-1 is plotted, the graph of FIG. 5 is obtained. Further, when the line L1-2 is drawn from the center of FIG. 3 in the direction orthogonal to L1-1 and the frequency distribution of the line L1-2 is plotted, the graph of FIG. 6 is obtained. In FIG.
  • 1 / XA having a high frequency is the most frequent pitch of the wavy uneven pattern in the light diffusing sheet 10.
  • 1 / XB and 1 / YB which are frequently used, are the mode diameters in the L1-1 direction and the L1-2 direction of the large number of convex portions in the light diffusing sheet 10, respectively. That is, 1 / XA is the mode pitch of the wavy uneven pattern, and 1 / (XB + YB) is the apparent mode diameter of a number of convex portions.
  • the orientation from the center means the direction of the periodic structure (uneven pattern 13) existing in FIG. 1A, and the distance from the center is the period of the periodic structure existing in FIG.
  • FIG. 1A Means the reciprocal.
  • XB is a position where the frequency is maximum in a portion passing through the ring of line L1-1 (not shown in FIG. 4)
  • YB is a line L1-2. This is the position where the frequency is maximum in the portion passing through the ring (not shown in FIG. 4).
  • the average value of the mode pitches obtained as described above for each photo is defined as the “mode pitch” of the wavy uneven pattern 13. That is, the “most frequent pitch” refers to the distance between the tops having the highest appearance frequency among the distances between the tops of the adjacent ridges.
  • the average value of the apparent mode diameter obtained as described above for each photograph is defined as the “apparent mode diameter” of the convex portion 14. That is, the “apparent mode diameter” refers to a diameter having the highest appearance frequency among the diameters of the convex portions formed on the concave / convex pattern.
  • the fine irregularities of the surface fine irregularities may have concave portions instead of convex portions, and the “apparent mode diameter” of the concave portions is the same as the “apparent mode diameter” of the convex portions. Desired.
  • the average height of the ridges 13a constituting the wavy uneven pattern 13 is preferably 4 to 7 ⁇ m, more preferably 5 to 6 ⁇ m. When the average height of the ridges 13a is within the above range, sufficient light diffusibility can be obtained.
  • the average height of the ridges 13a of the wavy uneven pattern 13 is measured and defined as follows. First, the fine unevenness forming surface of the light diffusive sheet 10 is observed with an atomic force microscope, and from the observation result, the surface obtained by cutting the wavy uneven pattern 13 along the Y direction is a longitudinal sectional view as shown in FIG. Get. And the height H of the said protruding item
  • line part 13 is calculated
  • the height H of the ridge portion 13a is set to H1 as a vertical distance between the top portion T of the ridge portion 13a and the bottom portion B1 of the ridge portion 13b located on one side of the ridge portion 13a.
  • H2 (H1 + H2) / 2.
  • the average height of the convex portions 14 is preferably 0.5 to 3 ⁇ m, more preferably 1 to 2 ⁇ m, and still more preferably 1.1 to 1.5 ⁇ m.
  • the anisotropy of the wavy uneven pattern 13 can be moderately weakened, and the diffusion angles in both the Y direction and the X direction can be easily controlled within the above range.
  • the average height of the convex part 14 is measured and defined as follows.
  • the cross-sectional view of FIG. 7 is obtained as described above.
  • the waveform is separated into a shape derived from the wavy uneven pattern 13 and a shape derived from the convex portion 14.
  • the waveform separation is performed using a shape derived from the wavy uneven pattern 13 as a sine curve.
  • the shape derived from the wavy uneven pattern 13 is subtracted from the cross-sectional view of FIG. 8 to obtain a cross-sectional view of only the shape derived from the convex portion 14 as shown in FIG.
  • H1 ′ is a vertical distance between the top portion T ′ of the convex portion 14 and the base line L ⁇ on one side of the convex portion 14
  • H2 ′ is the top portion T ′ of the convex portion 14. It is a vertical distance between the baseline L beta of the other side of the convex portion 14.
  • Such measurement is performed on 50 convex portions 14, and the average value of 50 data is defined as "average height of convex portions".
  • the occupation area ratio of the convex portions 14 in the fine irregularities of the light diffusing sheet 10 is preferably 30 to 70%, more preferably 40 to 60%, and further preferably 45 to 55%.
  • the occupation area ratio of the convex portion 14 is in the above range, the anisotropy of the wavy uneven pattern 13 can be moderately weakened, and the diffusion angles in both the Y direction and the X direction can be easily controlled within the above range.
  • ⁇ (%) S1 ⁇ 100 / S2 (where r in the formula is 1 ⁇ 2 (ie, radius) of the apparent mode diameter of the convex portion)
  • the light diffusive sheet 10 in the illustrated example is formed on one surface of the corrugated uneven pattern 13 mainly having diffusion in the Y direction, and the corrugated uneven pattern 13.
  • the pattern 13 has fine irregularities including a large number of convex portions 14 that moderately weaken the anisotropy of the pattern 13 and increase diffusion in the X direction. Therefore, when light is incident on the light diffusing sheet 10 from any one surface, a sufficient diffusion angle of, for example, 18 ° or more, preferably 23 ° or more, more preferably 25 ° or more is obtained in the Y direction. .
  • a sufficient 1/10 diffusion angle of (diffusion angle ⁇ 1.4 + 25 °) or less, preferably (diffusion angle ⁇ 1.4 + 22 °) or less, more preferably (diffusion angle ⁇ 1.4 + 20 °) or less is obtained.
  • a diffusion angle of, for example, 4 ° or more, preferably 8 ° or more, more preferably 10 ° or more can be obtained in the X direction.
  • a sufficient 1/10 diffusion angle of (diffusion angle ⁇ 1.6 + 25 °) or less, preferably (diffusion angle ⁇ 1.6 + 20 °) or less, more preferably (diffusion angle ⁇ 1.6 + 18 °) or less is obtained. .
  • the ridges 13a constituting the wavy uneven pattern 13 of the illustrated light diffusing sheet 10 are non-parallel to each other and meandering, and have no regularity. For this reason, the anisotropy of the uneven pattern 13 is moderately weakened, and the effect of increasing the diffusion angle in the X direction is considered to be more prominently combined with the effect of forming the convex portion 14. It is done.
  • a method of increasing the diffusion angle in the X direction a method of adding a light diffusing agent is also conceivable. However, the addition of a light diffusing agent tends to lower the light transmittance of the light diffusing sheet.
  • the method of increasing the diffusion angle in the X direction by specifically controlling fine irregularities as in the present invention it is not necessary to add a light diffusing agent, and even when it is added, the amount of addition Can be made in small quantities. Therefore, the light transmittance can be maintained high.
  • Such a light diffusing sheet 10 in the illustrated example is, for example, in a head-up display (HUD) system that clearly displays current speed information, car navigation information, and the like on a windshield of a car that is formed in a gently curved surface. It is preferably used as a diffusion member.
  • the light diffusing sheet 10 is also suitably used as a diffusing member for a projector; a diffusing member for a backlight of a television, a monitor, a notebook personal computer, a tablet personal computer, a smartphone, a mobile phone, or the like.
  • the light diffusive sheet 10 is also preferably used as a diffusing member or the like constituting the exit surface of the light guide member in a scanner light source in which LED light sources are arranged in a line, used in a copying machine or the like.
  • One aspect of the present invention is the use of the above-described surface fine irregularities as a light diffusing sheet or a light diffusing member, or a method of using the same. Further, when the surface fine irregularities of the present invention are used as a light diffusing sheet or a light diffusing member, the application destination thereof is as described above for a head-up display system, a backlight for a personal computer or a mobile phone, or Examples thereof include a diffusion member such as an emission surface of the light guide member.
  • the light diffusing sheet 10 in the illustrated example uses a light diffusing sheet forming original plate (light diffusing material forming original plate) having fine irregularities on the surface as a mold, and the light diffusing sheet forming original plate (hereinafter referred to as “original plate”). (Also referred to as)).
  • original plate the light diffusing sheet forming original plate
  • One aspect of the present invention is the use of the surface fine concavo-convex body as a light diffusing sheet or an original plate for producing a diffusing member.
  • the light diffusing sheet 10 in the illustrated example is a secondary transfer product obtained by transferring the fine irregularities of the original plate to obtain a primary transfer product, and then further transferring the fine irregularities of the primary transfer product.
  • the fine unevenness of the primary transfer product is a reverse pattern of the fine unevenness of the original plate, but the fine unevenness of the secondary transfer product is the same pattern as the fine unevenness of the original plate. Therefore, in this example, a surface fine uneven body having the same fine unevenness as the light diffusing sheet 10 in the illustrated example is manufactured as an original, and this is used as a transfer mold for secondary transfer, and the light diffusing sheet 10 in the illustrated example is produced. Is manufacturing.
  • the fine unevenness of the transfer product when n is an even number, the fine unevenness of the transfer product is the same pattern as the fine unevenness of the original plate, but when n is an odd number, the transfer product has The fine unevenness becomes a reversal pattern of the fine unevenness of the original.
  • the fine unevenness of the n-order transfer product when n is an n-order transfer product having an odd number and the fine unevenness of the original used for transfer has a convex part, the fine unevenness of the n-order transfer product (n is an odd number)
  • the convex part has a concave part that is inverted.
  • the fine irregularities of the surface fine irregularities of the present invention may be in the form of having concave portions instead of convex portions.
  • the surface fine irregularities of the present invention include not only the above-mentioned original plate and the original n-order transfer product (n is an even number) but also the original n-order transfer product (n is an odd number).
  • the manufacturing method of the light diffusable sheet 10 of the example of illustration which is a secondary transfer product is demonstrated.
  • the surface fine uneven body 20 shown in FIG. 11 is manufactured and used as an original.
  • the original plate has a base material 21 made of resin and a hard layer 22 provided on one entire surface of the base material 21, and the exposed surface of the hard layer 22 has the light diffusing sheet 10 in the illustrated example. Are formed in the same fine irregularities.
  • the hard layer 22 includes a matrix resin 22a and particles 22b dispersed in the matrix resin 22a.
  • the hard layer 22 is deformed so as to be folded, and the thickness t of the hard layer 22 (part where no particles exist). Is set smaller than the particle diameter d of the particles. Therefore, the hard layer 22 has a wavy uneven pattern 13 ′ (projection strip portion 13 a ′ and recess strip portion 13 b ′) formed by being deformed as folded, and each particle 22 b dispersed in the hard layer 22.
  • the contact surface of the base material 21 with the hard layer 22 has a concavo-convex shape following the shape of the hard layer 22 deformed as if folded.
  • the thickness t of the hard layer 22 is a portion of the hard layer 22 where the particles 22b are not present from a micrograph of a cross section (longitudinal cross section) obtained by cutting the surface fine irregularities 20 perpendicular to the surface direction. This is the average value of the numerical values obtained when randomly extracting more than one point and measuring the thickness of each part in the normal direction.
  • the particle diameter d of the particles 22b is a mode diameter (mode) measured by a laser diffraction / scattering particle size distribution analyzer for uniformly dispersed particles.
  • the surface fine concavo-convex body 20 shown in FIG. 11 is a lamination process in which a hard layer in which particles are dispersed in a matrix resin is provided on one side of a base film made of resin to form a laminated sheet. And a deformation step of deforming at least a hard layer of the laminated sheet so as to be folded.
  • the vertical cross section of each protruding line portion 13a ' is tapered from the proximal end side toward the distal end side.
  • the glass transition temperature Tg2 of the matrix resin 22a needs to be 10 ° C. or more higher than the glass transition temperature Tg1 of the resin constituting the substrate 21.
  • the particles 22b need to be made of a material whose particle shape does not change due to heat at a temperature lower than a temperature 10 ° C. higher than the glass transition temperature of the resin constituting the substrate 21.
  • the particle shape does not change means that the particle shape and particle diameter do not change before and after heating.
  • the resin constituting the base material 21 and the matrix resin 22a need to be selected so that the difference between these glass transition temperatures (Tg2 ⁇ Tg1) is 10 ° C. or more. 20 degreeC or more is preferable and 30 degreeC or more is more preferable.
  • (Tg2 ⁇ Tg1) is 10 ° C. or higher, processing such as heat shrinkage can be easily performed at a temperature between Tg2 and Tg1 in a deformation process described later.
  • the temperature between Tg2 and Tg1 is the processing temperature, it can be processed under the condition that the Young's modulus of the base material is higher than the Young's modulus of the matrix resin 22a.
  • the uneven pattern 13 ′ can be easily formed.
  • the processing temperature is a temperature at which the hard layer 22 is deformed so as to be folded at least in the deformation process (for example, a heating temperature at the time of thermal contraction).
  • (Tg2 ⁇ Tg1) is preferably 550 ° C. or less. More preferably, it is 200 ° C. or lower. That is, in one embodiment of the present invention, (Tg2-Tg1) is preferably 10 to 550 ° C, more preferably 30 to 200 ° C.
  • (Tg2-Tg1) is preferably 10 to 550 ° C, more preferably 30 to 200 ° C.
  • the difference in Young's modulus between the base material 21 and the matrix resin 22a at the processing temperature in the deformation process described later is preferably 0.01 to 300 GPa because the wavy uneven pattern 13 ′ can be easily formed. More preferably, it is 1 to 10 GPa.
  • the Young's modulus is a value measured according to JIS K 7113-1995.
  • Tg1 is preferably ⁇ 150 to 300 ° C., more preferably ⁇ 120 to 200 ° C. There is no resin having a Tg1 lower than ⁇ 150 ° C., and if the Tg1 is 300 ° C. or lower, the temperature can be easily raised and heated to the above processing temperature.
  • the Young's modulus of the resin constituting the substrate 21 at the above processing temperature is preferably 0.01 to 100 MPa, and more preferably 0.1 to 10 MPa. If the Young's modulus of the resin constituting the base material 21 is 0.01 MPa or more, it is a hardness that can be used as the base material, and if it is 100 MPa or less, the hard layer 22 is deformed following the deformation at the same time. It is possible softness.
  • the material constituting the particles 22b at least one kind of material whose particle shape does not change by heat can be used at a temperature lower than 10 ° C. higher than the glass transition temperature of the resin constituting the substrate 21.
  • the glass transition temperature Tg3 is the glass transition temperature of the matrix resin. It is necessary to satisfy the same condition as Tg2, that is, (Tg3-Tg1) should be selected so as to be 10 ° C. or higher. (Tg3-Tg1) is more preferably 20 ° C. or higher, and 30 ° C. or higher. Further preferred.
  • the particles 22b are not deformed and melted, and the convex portions 14 ′ are reliably formed.
  • the material constituting the particles 22b is a material that does not have a glass transition temperature, such as an internally cross-linked resin
  • the Vicat softening temperature (as defined in JIS K7206) satisfies the above-described condition, that is, It is preferably higher than the glass transition temperature of the resin constituting the substrate 21 by 10 ° C. or higher, preferably higher by 20 ° C. or higher, more preferably higher by 30 ° C. or higher.
  • glass transition temperature Tg3 corresponds also to the Vicat softening temperature, when the particle
  • Tg2 and Tg3 are preferably 40 to 400 ° C, and more preferably 80 to 250 ° C. If Tg2 and Tg3 are 40 ° C. or higher, the above-mentioned processing temperature can be increased to room temperature or higher, which is useful, and matrix resin 22a or Tg3 having Tg2 higher than 400 ° C. is higher than 400 ° C. Use of the particles 22b is less necessary from the viewpoint of economy.
  • the Young's modulus of the matrix resin 22a at the above processing temperature is preferably 0.01 to 300 GPa, more preferably 0.1 to 10 GPa. If the Young's modulus of the matrix resin 22a is 0.01 GPa or more, sufficient hardness is obtained from the Young's modulus at the processing temperature of the resin constituting the substrate 21, and after the wavy uneven pattern 13 'is formed, The hardness is sufficient to maintain the uneven pattern 13 ′. Use of a resin having a Young's modulus exceeding 300 GPa as the matrix resin 22a is less necessary from the viewpoint of economy.
  • the resin constituting the substrate 21 examples include polyesters such as polyethylene terephthalate, polyolefins such as polyethylene and polypropylene, polystyrene resins such as styrene-butadiene block copolymers, polyvinyl chloride, polyvinylidene chloride, and polydimethylsiloxane.
  • polyesters such as polyethylene terephthalate, polyolefins such as polyethylene and polypropylene, polystyrene resins such as styrene-butadiene block copolymers, polyvinyl chloride, polyvinylidene chloride, and polydimethylsiloxane.
  • resins such as silicone resin, fluororesin, ABS resin, polyamide, acrylic resin, polycarbonate, and polycycloolefin.
  • polyester and polycarbonate are preferable because a desired uneven shape can be easily obtained after shrinkage.
  • the resin preferably has a mass average molecular weight of 1,000 to 1
  • the mass average molecular weight refers to a value measured using gel permeation chromatography.
  • the eluent one appropriately selected from tetrahydrofuran, chloroform, hexafluoroisopropanol and the like can be used.
  • the molecular weight standard substance a material appropriately selected from known molecular weight polystyrene, polymethyl methacrylate and the like can be used.
  • the measurement temperature can be appropriately selected within the range of 35 to 50 ° C.
  • the matrix resin 22a is selected according to the type of the base material 21 so that the glass transition temperature Tg2 satisfies the above-mentioned conditions.
  • polyvinyl alcohol, polystyrene, acrylic resin, styrene-acrylic copolymer, styrene -Acrylonitrile copolymer, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, polyethersulfone, fluororesin, etc. can be used.
  • acrylic resins are preferable in terms of transparency.
  • the matrix resin preferably has a mass average molecular weight of 1,000 to 10,000,000, more preferably 10,000 to 2,000,000.
  • the mass average molecular weight refers to a value measured using gel permeation chromatography.
  • the eluent one appropriately selected from tetrahydrofuran, chloroform, hexafluoroisopropanol and the like can be used.
  • the molecular weight standard substance a material appropriately selected from known molecular weight polystyrene, polymethyl methacrylate and the like can be used.
  • the measurement temperature can be appropriately selected within the range of 35 to 50 ° C.
  • the matrix resin 22a may be used alone, but may be appropriately used in accordance with the purpose of adjusting the mode pitch, average height, and orientation degree of the wavy uneven pattern. For example, resins of the same type but different in glass transition temperature can be used in combination, or different types of resins can be used in combination.
  • the resin constituting the particles 22b is selected according to the type of the base material 21 so that the glass transition temperature Tg3 (or Vicat softening point) satisfies the above-described conditions, for example, acrylic thermoplastic resin particles, Examples thereof include polystyrene-based thermoplastic resin particles, acrylic-based crosslinked resin particles, and polystyrene-based crosslinked resin particles.
  • acrylic thermoplastic resin particles examples thereof include polystyrene-based thermoplastic resin particles, acrylic-based crosslinked resin particles, and polystyrene-based crosslinked resin particles.
  • the inorganic material include glass beads.
  • the thickness of the substrate 21 is preferably 30 to 500 ⁇ m. If the thickness of the base material is 30 ⁇ m or more, the manufactured original plate is hardly broken, and if the thickness is 500 ⁇ m or less, the original plate can be easily thinned.
  • the thickness of the base material 21 is randomly extracted from a microphotograph of a cross section (longitudinal section) obtained by cutting the surface fine irregularities (original plate) 20 of FIG. It is an average value of the obtained numerical values when the thickness of the substrate 21 is measured. Further, in order to support the substrate 21, a resin support having a thickness of 5 to 500 ⁇ m may be provided separately.
  • the thickness t of the hard layer 22 is preferably more than 0.05 ⁇ m and not more than 5 ⁇ m, and more preferably 0.1 to 2 ⁇ m. If the thickness t of the hard layer 22 is more than 0.05 ⁇ m and not more than 5 ⁇ m, a wavy uneven pattern 13 ′ suitable as a light diffuser can be formed. Moreover, you may form a primer layer between the base material 21 and the hard layer 22 for the purpose of improving adhesiveness or forming a finer structure.
  • the particle diameter d of the particles 22b needs to be larger than the thickness t of the hard layer 22, and is set according to the thickness t of the hard layer 22. Further, the apparent mode diameter of the convex portion 14 of the illustrated example of the light diffusing sheet 10 manufactured using the surface fine uneven body 20 of FIG. 11 as an original plate is appropriately set so as to be within the above-mentioned preferable range. Is done.
  • a preferred particle diameter d is, for example, 5 to 10 ⁇ m, and more preferably 5 to 8 ⁇ m.
  • the fine surface irregularities 20 in FIG. 11 can also be used as a light diffuser instead of the original.
  • a transparent material is used for the material used for the base material 21, the matrix resin 22 a, and the particles 22 b so that the surface fine uneven body 20 sufficiently functions as a light diffuser.
  • the surface fine irregularities 20 in FIG. 11 are a laminated sheet 30 as shown in FIG. 12, that is, a matrix resin on one side (flat surface) of a base film 31 made of resin, and particles 22b dispersed in the matrix resin.
  • the substrate film 31 corresponds to the substrate 21 of the surface fine irregularities 20 of FIG.
  • the term “flat” refers to a surface having a center line average roughness of 0.1 ⁇ m or less as described in JIS B0601.
  • a coating liquid (dispersion or solution) containing matrix resin 22a, particles 22b, and a solvent is prepared, and the coating liquid is applied to one surface of the base film 31 by a spin coater or a bar coater.
  • the hard layer 32 having a thickness t ′ of more than 0.05 ⁇ m and 5.0 ⁇ m or less is formed.
  • the hard layer 32 at this time is not deformed so as to be folded.
  • the hard layer 32 is obtained by laminating a hard layer (a film in which particles are dispersed in a matrix resin) prepared in advance on the base film. You may provide by the method to do.
  • the base film 31 is preferably a uniaxial heat shrinkable film made of resin.
  • the uniaxial heat-shrinkable film by heating the laminated sheet 30 in the next deformation step, the hard layer 32 can be easily deformed so as to be folded and the wavy uneven pattern 13 ′ can be formed. Further, according to this method, it is possible to form irregular ridges 13a 'that meander each other and are not parallel to each other.
  • the resin constituting the uniaxial heat-shrinkable film is as already exemplified as the resin constituting the base material 21.
  • a shrink film such as a polyethylene terephthalate shrink film, a polystyrene shrink film, a polyolefin shrink film, or a polyvinyl chloride shrink film can be preferably used.
  • these shrink films those that shrink 50 to 70% in the uniaxial direction are preferable. If a shrink film that shrinks by 50 to 70% is used, the deformation rate can be increased to 50% or more. As a result, it is possible to form a wavy uneven pattern 13 ′ having a preferable mode pitch and the height of the protruding portion 13a ′.
  • the deformation rate is (length before deformation ⁇ length after deformation) ⁇ 100 / (length before deformation) (%). Alternatively, (deformed length) ⁇ 100 / (length before deformation) (%).
  • the uneven pattern 13 ′ can be formed more easily.
  • the rate is preferably 0.01 to 300 GPa, more preferably 0.1 to 10 GPa.
  • the glass transition temperature Tg2 of the matrix resin 22a and the glass transition temperature Tg3 of the particles 22b are the base materials. It is important to select and combine the materials so that the glass transition temperature Tg1 of the film 31 is 10 ° C. or higher.
  • base film 31 When 30 is used, a wavy uneven pattern 13 ′ in which the most frequent pitch is 3 to 20 ⁇ m and the average height of the protrusions 13 a ′ is 4 to 7 ⁇ m is easily formed through the following deformation process.
  • the matrix resin 22a is, for example, an acrylic resin, one or more of methyl ethyl ketone and methyl isobutyl ketone can be used.
  • the concentration of the matrix resin 22a in the coating solution is preferably 5 to 10% by mass as the net amount (solid content) from the viewpoint of coating properties.
  • the amount of the particles 22b is preferably 10 to 50 parts by mass, and more preferably 20 to 30 parts by mass with respect to 100 parts by mass of the net amount of the matrix resin 22a.
  • the occupation area ratio of the convex portion 14a ′ or the concave portion in the fine irregularities to be formed can be controlled within the above-described preferable range.
  • the net amount (solid content) refers to the ratio of the mass of the solid content remaining after the solvent in the coating solution volatilizes with respect to the mass (100 mass%) of the coating solution.
  • the thickness t ′ of the hard layer 32 formed in the laminating step may be continuously changed as long as it is in the range of more than 0.05 ⁇ m and 5.0 ⁇ m or less. In that case, the pitch and depth of the concavo-convex pattern formed by the deformation process are continuously changed.
  • (Deformation process) 11 is obtained by heating the laminated sheet 30 obtained as described above and causing the base film 31 of the laminated sheet 30 to be thermally contracted.
  • the well-known method disclosed by the Japan patent 4683011 etc. is employable, for example.
  • the heating method include a method of passing through hot air, steam, hot water, or far infrared rays. Among them, a method of passing through hot air or far infrared rays is preferable because it can be uniformly contracted.
  • the heating temperature (processing temperature) at the time of heat shrinking the base film 31 is preferably set to a temperature between Tg2 and Tg1, and specifically, the type of the base film 31 to be used and the intended uneven pattern. It is preferable to select appropriately according to the pitch of 13 ', the height of the protruding portion 13a', and the like.
  • the height of the ridge portion 13a ′ increases as the height increases. Therefore, in order to set the most frequent pitch of the concavo-convex pattern 13 ′ and the height of the ridge 13 a ′ to desired values, it is necessary to appropriately select the above conditions.
  • the surface fine uneven body 20 having the structure as shown in FIG. 11 can also be manufactured by the following methods (1) to (4).
  • (1) A method of forming a laminated sheet by providing an undeformed hard layer on one side of a flat base film, and compressing the whole laminated sheet in one direction along the surface. When the glass transition temperature of the base film is lower than room temperature, the laminated sheet is compressed at room temperature. When the glass transition temperature of the base film is higher than the room temperature, the laminated sheet is compressed above the glass transition temperature of the base material and hard. Performed below the glass transition temperature of the layer.
  • An undeformed hard layer is provided on one side of a flat base film to form a laminated sheet, the laminated sheet is stretched in one direction, and the direction perpendicular to the stretching direction is shrunk to form a hard layer.
  • a method of compressing in one direction along the surface When the glass transition temperature of the base film is lower than room temperature, the lamination sheet is stretched at room temperature. When the glass transition temperature of the base film is room temperature or higher, the stretching of the laminated sheet is equal to or higher than the glass transition temperature of the base film. It is performed below the glass transition temperature of the hard layer.
  • a flat base film formed of an uncured ionizing radiation curable resin is laminated with an undeformed hard layer to form a laminated sheet, and the base film is cured by irradiation with ionizing radiation.
  • An undeformed hard layer is laminated on a flat base film swelled by swelling a solvent to form a laminated sheet, and the solvent in the base film is dried and contracted by removing it. The method of compressing the hard layer laminated
  • a resin solution or dispersion containing particles is applied to one side of a flat base film using a spin coater or bar coater, and a solvent is used.
  • a drying method and a method in which a hard layer prepared in advance is laminated on one side of a flat base film examples include a method of compressing the laminated sheet by sandwiching one end portion of the laminated sheet and the opposite end portion thereof with a vise or the like.
  • examples of the method of stretching the laminated sheet in one direction include a method of stretching by stretching one end portion of the laminated sheet and the opposite end portion thereof.
  • examples of the ionizing radiation curable resin include an ultraviolet curable resin and an electron beam curable resin.
  • the solvent is appropriately selected according to the type of resin constituting the base film.
  • the drying temperature of the solvent is appropriately selected according to the type of solvent.
  • the same components as those used in the method (1) can be used, and the thickness can be the same.
  • the formation method of a lamination sheet is the same as the method of (1), the method of apply
  • the fine irregularities formed on the surface of the hard layer 22 of the surface fine irregularities (original) 20 are transferred to another material, and a primary transfer product having a reverse pattern of the fine irregularities of the original on the surface is obtained.
  • the reverse pattern of the primary transfer product is transferred to another material to obtain the light diffusive sheet 10 of the illustrated example which is a secondary transfer product.
  • a publicly known method disclosed in Japanese Patent No. 4683011 can be adopted.
  • One aspect of the present invention is a method for producing a surface fine unevenness using the surface fine unevenness described above as an original plate.
  • an uncured ionizing radiation curable resin containing a release agent is adjusted to a thickness of, for example, 3 to 30 ⁇ m with respect to the fine unevenness of the surface fine unevenness 20 of FIG.
  • a coater such as a die coater, roll coater, or bar coater
  • the original is peeled off to obtain a primary transfer product.
  • the primary transfer product has a reversal pattern of fine irregularities of the original plate.
  • a transparent substrate 11 made of PET is prepared, and an uncured ionizing radiation curable resin is applied on one surface thereof with a thickness that sufficiently covers fine irregularities.
  • the surface of the applied uncured ionizing radiation curable resin is pressed against the surface having the reversal pattern of the previously obtained primary transfer product and cured by irradiation with ionizing radiation.
  • the next transfer product is peeled off. Irradiation with ionizing radiation may be performed from either one of the primary transfer product side and the transparent PET substrate side having ionizing radiation transparency. Thereby, it consists of the transparent base material 11 which consists of PET, and the surface layer 12 of the ionizing radiation curable resin cured material formed on the one side, and FIG.
  • the light diffusable sheet (secondary transfer product) 10 of FIG. 2 is obtained.
  • the ionizing radiation curable resin examples include an ultraviolet curable resin and an electron beam curable resin.
  • the type of ionizing radiation to be irradiated is appropriately selected according to the type of resin.
  • the ionizing radiation often means ultraviolet rays and electron beams, but in the present specification, visible rays, X-rays, ion rays and the like are also included.
  • Uncured ionizing radiation curable resins include epoxy acrylate, epoxidized oil acrylate, urethane acrylate, unsaturated polyester, polyester acrylate, polyether acrylate, vinyl / acrylate, polyene / acrylate, silicon acrylate, polybutadiene, and polystyrylmethyl methacrylate. 1 type selected from monomers such as prepolymers such as aliphatic acrylate, alicyclic acrylate, aromatic acrylate, hydroxyl group-containing acrylate, allyl group-containing acrylate, glycidyl group-containing acrylate, carboxy group-containing acrylate, halogen-containing acrylate, etc. The thing containing the above component is mentioned.
  • the uncured ionizing radiation curable resin is preferably diluted with a solvent or the like.
  • a fluorine resin, a silicone resin, or the like may be added to the uncured ionizing radiation curable resin.
  • a photopolymerization initiator such as acetophenones and benzophenones to the uncured ionizing radiation curable resin.
  • thermosetting resin such as uncured melamine resin, urethane resin or epoxy resin
  • thermoplastic resin such as acrylic resin, polyolefin or polyester.
  • the specific method and material to be transferred are not limited.
  • thermosetting resin for example, a method of applying a liquid uncured thermosetting resin to fine irregularities and curing it by heating is mentioned.
  • thermoplastic resin a sheet of thermoplastic resin is used. There is a method of heating and softening while pressing against fine irregularities and then cooling.
  • a method using a plating roll described in Japanese Patent No. 4683011 is also exemplified. Specifically, first, a long sheet-like material is manufactured as an original plate, the original plate is rounded and attached to the inside of a cylinder, plating is performed with a roll inserted inside the cylinder, and the roll is removed from the cylinder. Take out and obtain a plating roll (primary transfer product). Next, a light diffusive sheet (secondary transfer product) is obtained by transferring the fine irregularities of the plating roll.
  • a single wafer type or a web type can be used as the original plate. If a web type master is used, a web type primary transfer product and a secondary transfer product can be obtained.
  • a stamp method using the single-wafer type original as a flat plate, a roll imprint method using a single-wafer type original wound around a roll as a cylindrical die, and the like can be applied.
  • a single-wafer type master may be arranged inside the mold of the injection molding machine. However, in the method using these single-wafer type masters, it is necessary to repeat the transfer many times in order to mass-produce the light spreading powder sheet as shown in the illustrated example.
  • a method of forming a large number of concave portions or convex portions on the formed concave / convex pattern the following methods (5) to (8) can be mentioned.
  • (5) A method of cutting with a rotary precision cutting machine.
  • (6) A method of forming a recess by pressing a projection having the same size and diameter as the recess or the protrusion onto the wavy uneven pattern.
  • (7) A method of forming a convex portion formed of the resin or the inorganic substance by adhering a fine resin or inorganic melt to the wavy uneven pattern and then solidifying it by cooling.
  • the inkjet printing method in the method (7) or (8) a large number of concave portions or convex portions can be formed on the wavy uneven pattern with high accuracy.
  • a hard layer is formed using a coating liquid that does not contain particles and contains a matrix resin and a solvent, and is formed into a wavy uneven pattern by a deformation process (a large number of recesses or protrusions have not yet been formed) )
  • a deformation process a large number of recesses or protrusions have not yet been formed
  • a plurality of concave portions or convex portions may be formed on the concavo-convex pattern by the above methods (5) to (8). And by transferring this as an original plate, it is possible to produce a surface fine unevenness.
  • the primary transfer product obtained by using the surface fine irregularities 20 produced by the laminating process and the deformation process as an original plate and the n-order transfer product (n is an integer of 3 or more) are used as the light diffusive sheet. If it is a transfer product, it is not limited to a secondary transfer product. Moreover, you may transfer a fine unevenness
  • the particles used for forming the hard layer resin particles and inorganic particles can be used, and any material can be used as long as it is not melted or deformed in the deformation process or the process of transferring fine irregularities. There may be.
  • the particles are transparent particles, preferably acrylic cross-linked resin particles, glass It is necessary to use beads, polystyrene-based crosslinked resin particles, and the like.
  • the sheet-like material was illustrated as a surface fine unevenness
  • the fine unevenness may be formed in any part depending on the purpose as long as it is at least a part of the surface of the surface fine unevenness.
  • the surface fine unevenness is a sheet-like material, it may be formed on only one surface, on both surfaces, or may be formed on only part of each surface, You may form in at least one part of the surrounding surface (end surface) of a thing.
  • the surface fine irregularities are three-dimensional molded bodies, they may be formed on the entire surface or only on a part thereof.
  • a diffusion member for a HUD system a diffusion member for a projector; a diffusion member for a backlight of a television, a monitor, a notebook personal computer, a tablet personal computer, a smartphone, a mobile phone, etc .;
  • a scanner light source in which LED light sources are linearly arranged, it can be suitably used as a diffusing member that constitutes at least an emission surface of a light guide member.
  • the wavy concavo-convex pattern comprises a plurality of ridges arranged along a first direction, and a ridge between the plurality of ridges, The ridge lines of the plurality of ridges meander non-parallel to each other when viewed from the normal direction of the substrate of the surface fine irregularities, The most frequent pitch in the first direction of the plurality of ridges is 3 to 20 ⁇ m;
  • the apparent mode diameter of the concave portion or convex portion is 1 to 10 ⁇ m,
  • the surface fine irregularities, wherein the concave or convex shape is hemispherical.
  • the fine unevenness has a wavy uneven pattern and a recess or protrusion formed on the wavy uneven pattern
  • the wavy concavo-convex pattern comprises a plurality of ridges arranged along a first direction, and a ridge between the plurality of ridges, The ridge lines of the plurality of ridges meander non-parallel to each other when viewed from the normal direction of the surface fine irregularities,
  • the most frequent pitch in the first direction of the plurality of ridges is 3 to 20 ⁇ m;
  • the apparent mode diameter of the concave portion or convex portion is 1 to 10 ⁇ m,
  • the shape of the concave portion or convex portion is hemispherical,
  • the surface fine concavo-convex body in which the occupying ratio of the concave portion or the convex portion is 30 to 70 mass% with respect to the
  • a hard layer is provided by applying a coating liquid containing a matrix resin and particles so that the thickness after drying is more than 0.05 ⁇ m and 5.0 ⁇ m or less.
  • the resin is a polyester resin
  • the matrix resin is a group consisting of polyvinyl alcohol, polystyrene, acrylic resin, styrene-acrylic copolymer, styrene-acrylonitrile copolymer, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycarbonate, polyethersulfone, and fluororesin.
  • the particles are at least one particle selected from the group consisting of acrylic thermoplastic resin particles, polystyrene thermoplastic resin particles, acrylic crosslinked resin particles, polystyrene crosslinked resin particles, and glass beads, At a temperature below 10 ° C. higher than the glass transition temperature of the resin constituting the substrate film, the particle shape does not change, The particle size is 5-10 ⁇ m, The method for producing a fine surface irregularity, wherein the cured layer contains 10 to 50 parts by mass of the particles with respect to 100 parts by mass of the matrix resin.
  • SC807 polyethylene terephthalate uniaxial heat shrinkable film
  • the mixture was mixed at a mass ratio of 70:30, and in addition to toluene, a coating liquid (1) having a solid content concentration of 7.7 mass% was obtained.
  • the said acrylic resin A is solid content concentration 20 mass%
  • concentration in this example are the values calculated by the net amount (solid content amount). The following examples are also calculated with the net amount.
  • the laminated sheet is heated at 150 ° C. for 1 minute using a hot air oven to heat shrink the polyethylene terephthalate uniaxial heat shrinkable film to 49% of the length before heating in the uniaxial direction (deformation rate). 51%), the hard layer was deformed to be folded. Thereby, the surface fine uneven sheet
  • An uncured UV curable resin A (manufactured by Soken Chemical Co., Ltd.) containing a release agent is applied to the surface of the surface fine uneven surface of the obtained surface fine uneven sheet (original) so as to have a thickness of 20 ⁇ m and irradiated with ultraviolet rays. And cured, and then peeled to obtain a primary transfer product having a reversal pattern of fine unevenness of the surface fine unevenness sheet.
  • an uncured UV curable resin B manufactured by Sony Chemical Co., Ltd. was applied to one side of a transparent PET base material (“A4300” manufactured by Toyobo Co., Ltd., thickness: 188 ⁇ m) to a thickness of 20 ⁇ m.
  • the surface of the primary transfer product having the above reversal pattern is pressed against the ultraviolet curable resin B, cured by irradiating with ultraviolet rays, and after curing, the primary transfer product is peeled off, and then on the transparent PET substrate.
  • Example 2 A light diffusing sheet was obtained in the same manner as in Example 1 except that the following coating liquid (2) was used instead of the coating liquid (1) in Example 1.
  • Example 3 A light diffusing sheet was obtained in the same manner as in Example 1 except that the following coating liquid (3) was used instead of the coating liquid (1) in Example 1.
  • Example 1 A light diffusing sheet was obtained in the same manner as in Example 1 except that the following coating liquid (4) was used instead of the coating liquid (1) in Example 1.
  • Example 4 A light diffusing sheet was obtained in the same manner as in Example 1 except that the following coating liquid (5) was used instead of the coating liquid (1) in Example 1.
  • Example 5 A light diffusing sheet was obtained in the same manner as in Example 1 except that the following coating liquid (6) was used instead of the coating liquid (1) in Example 1.
  • Example 6 In Example 1, coating was performed by a bar coater (Meyer bar # 20) so that the thickness t ′ of the hard layer after coating and drying was 3 ⁇ m, and a polyethylene terephthalate uniaxial heat-shrinkable film was uniaxially before heating. A light diffusing sheet was obtained in the same manner as in Example 1 except that the film was thermally shrunk to 60% of the length (40% as the deformation rate).
  • Example 7 Nickel was deposited to a thickness of 500 ⁇ m on the surface of the surface fine uneven sheet (original) obtained by the same method as in Example 1 by nickel electroforming. Subsequently, the deposited nickel was peeled from the surface fine uneven sheet (original) to obtain a nickel secondary original having the surface fine unevenness transferred on the surface. The nickel secondary original plate was incorporated into a mold of an injection molding machine, and injection molding of an acrylic resin was performed to obtain an injection molded product having fine irregularities transferred on the surface.
  • the obtained injection-molded product is a rectangular parallelepiped of 300 mm ⁇ 10 mm ⁇ 2 mm, in which fine irregularities are transferred to one surface of a pair of 2 mm ⁇ 300 mm surfaces, and the other surface is a smooth surface.
  • the shape of the diffused light (projected image) of the red laser pointer projected on white paper was visually evaluated in four stages. The results are shown in Table 1.
  • a luminance meter SR-3 manufactured by Topcon Co., Ltd. was placed at a position 1 m away from the light diffusing sheet and the injection molded product on the opposite surface side in the normal direction, and the luminance was measured. The results are shown in Table 1.
  • luminance of Table 1 is a relative brightness
  • the injection molded product manufactured in Example 7 was a rectangular parallelepiped, the surface on which fine irregularities were formed and the smooth surface were parallel.
  • the smooth surface parallel to the surface on which the fine irregularities are formed is obtained by appropriately cutting the injection molded product. It is preferable to use the sample that has been cut out as a sample, and to use the sample in the above measurements (2) to (5).
  • the diffusion angles in the X and Y directions are moderately large, and the 1/10 diffusion angles in the Y and X directions are
  • the respective values were (diffusion angle ⁇ 1.4 + 25 °) or less and (diffusion angle ⁇ 1.6 + 25 °) or less, and the relative luminance was sufficiently large. Therefore, it has been understood that these can be suitably used in, for example, a head-up display system in which information such as a traveling speed needs to be clearly diffused on the windshield of an automobile.
  • the light diffusing sheets of Examples 1 to 3 and the injection-molded product of Example 7 have a large diffusion angle in the X direction while maintaining a very high diffusion angle in the Y direction, and a balance with relative luminance. Also, it had very high performance.
  • the diffusion angle in the Y direction is sufficiently large, but the diffusion angle in the X direction is very small and the anisotropy is too high. It was understood that it was unsuitable for use.
  • the light diffusable sheet of each Example had sufficient light transmittance.
  • the injection molded product of Example 7 can be suitably used in a light guide member of a scanner light source in which LED light sources are arranged in a line, which is used in a copying machine or the like.
PCT/JP2014/057345 2013-03-18 2014-03-18 表面微細凹凸体および表面微細凹凸体の製造方法 WO2014148492A1 (ja)

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