WO2017047426A1

WO2017047426A1 - Method for producing antifogging film

Info

Publication number: WO2017047426A1
Application number: PCT/JP2016/075947
Authority: WO
Inventors: 俊哉三田; 祐依松浦; 永周孤島
Original assignee: 富士フイルム株式会社
Priority date: 2015-09-14
Filing date: 2016-09-05
Publication date: 2017-03-23
Also published as: CN108026305B; CN108026305A; JP6444284B2; JP2017057242A

Abstract

Provided is a method for producing an antifogging film having initial antifogging properties and long-term antifogging properties. According to the present invention, an antifogging film is produced by saponifying a first film surface of a cellulose acylate film by means of antifogging film production facilities. An application device of a saponification unit applies a saponification liquid to the cellulose acylate film. The saponification liquid contains an alcohol having from 2 to 3 (inclusive) carbon atoms, an alkali and water. The alcohol is applied to the first film surface of the cellulose acylate film at a coating rate of 17 g/m² or more. An infrared heater heats the cellulose acylate film, to which the saponification liquid has been applied, and maintains the temperature of the first film surface within the range of from 40°C to 80°C (inclusive) for a time period of from 20 seconds to 120 seconds (inclusive).

Description

Method for producing anti-fogging film

The present invention relates to a method for producing an antifogging film.

Mirrors in bathrooms and vanities, frozen showcases, and eyeglasses can cause water droplets to adhere to the surface due to condensation, which reduces visibility. Therefore, an antifogging film is used in order to suppress a decrease in visibility. As the antifogging film, there is a cellulose acylate film in which at least one film surface is subjected to a hydrophilic treatment. Examples of the hydrophilic treatment include actinic ray irradiation, plasma treatment, and saponification treatment with alkali.

For example, in JP-A-2014-224213, any hydrophilic treatment such as active ray irradiation, plasma treatment, corona discharge treatment, or saponification treatment with alkali is performed as a hydrophilic treatment of the cellulose acylate film, thereby preventing the cellulose acylate film. A method for producing a hazy film is described. This antifogging film comprises a methylene chloride soluble layer and a methylene chloride insoluble layer. The methylene chloride insoluble layer is the antifogging layer.

Japanese Patent Application Laid-Open No. 2013-99879 also describes a method for producing an antifogging film by performing a saponification treatment as a hydrophilic treatment. As the saponification treatment, a method of immersing the cellulose acylate film in an aqueous alkali solution and a method of applying an aqueous alkali solution to the cellulose acylate film are described, and the method of immersing is preferred.

JP 2012-145632 also describes a method for producing an antifogging film by immersing a cellulose acylate film in a saponification solution in the saponification solution.

In JP 2009-74000 A and JP 2004-182858 A, a saponification solution is applied to a cellulose acylate film to saponify, and a mixed solution containing an organic solvent such as alcohol is used as the saponification solution. Are listed.

According to the methods described in JP2013-99879A and JP2012-145632A, the obtained antifogging film is excellent in initial antifogging property, which is a function of preventing instantaneous dew condensation. There is no long-term anti-fogging property, that is, no function to prevent condensation for a long time, and its application is limited. Similarly, the antifogging film obtained by the method described in JP-A-2014-224213 has no long-term antifogging property. In the methods described in JP2009-74000A and JP2004-182858A, the antifogging film may not exhibit long-term antifogging properties.

Therefore, an object of the present invention is to provide a method for producing an antifogging film having an initial antifogging property and a long-term antifogging property.

In order to achieve the above object, the method for producing an anti-fogging film of the present invention comprises an alcohol coating step, a saponification solution coating step, and a temperature holding step, and the cellulose acylate film is saponified by alkali. A fog film is produced. In the alcohol application step, an alcohol having 2 to 3 carbon atoms is applied to one film surface of the cellulose acylate film in an amount of at least 17 g per 1 m ² . In the saponification solution coating step, a saponification solution containing alkali and water is applied to one film surface. In the temperature holding step, the temperature of the film surface is held in the range of 40 ° C. or more and 80 ° C. or less for 20 seconds or more and 120 seconds or less by heating the cellulose acylate film coated with the saponification solution.

The saponification solution application step includes an alcohol application step, and it is preferable to apply the saponification solution containing the alcohol.

The coating amount of alkali on one film surface is preferably at least 0.3 g per 1 m ² .

As the next step of the temperature holding step, it has one of a washing step for washing the cellulose acylate film and a neutralization step for neutralizing the alkali contained in the cellulose acylate film with an acid. It is preferred to stop saponification.

In the temperature holding step, the cellulose acylate film is preferably heated by an infrared heater that emits infrared rays, and the infrared heater more preferably irradiates the other film surface of the cellulose acylate film with infrared rays.

In the cellulose acylate film to be subjected to the saponification solution coating step, it is preferable that the mass of the plasticizer having a molecular weight of less than 500 is at most 4% with respect to the mass of the cellulose acylate.

The cellulose acylate film used in the saponification solution coating step preferably contains, as a plasticizer, an ester oligomer having a repeating unit containing an ester bond of a dicarboxylic acid and a diol and having a molecular weight of 500 or more and 10,000 or less. The dicarboxylic acid is an aliphatic dicarboxylic acid having 2 to 10 carbon atoms, and the diol is preferably an aliphatic diol having 2 to 10 carbon atoms.

According to the present invention, an antifogging film excellent in initial antifogging property and long-term antifogging property can be obtained.

It is a cross-sectional schematic diagram of an anti-fogging film. It is the schematic of an anti-fogging film manufacturing equipment. It is a graph showing the relationship between the contact angle 15 seconds after dropping pure water, and the time which hold | maintains temperature at a temperature holding process.

1, the antifogging film 10 includes a film base 11 and a saponified layer 12. The thickness T10 of the anti-fogging film 10 is not specifically limited, For example, it shall be in the range of 10 micrometers or more and 200 micrometers or less. In the present embodiment, the thickness T10 is set to 40 μm, for example.

The film base 11 is a film body of the antifogging film 10 and also functions as a support for supporting the saponified layer 12. The film base 11 is made of cellulose acylate. In this embodiment, the cellulose acylate is cellulose triacetate (hereinafter referred to as TAC, TAC is an abbreviation for triacetyl cellulose), but may be other cellulose acylate different from TAC. The film base 11 does not contain saponified cellulose acylate.

The film base 11 has the same composition as the cellulose acylate film 37 because it is the remainder that has not been saponified by saponification of the cellulose acylate film 37 (see FIG. 2) as will be described later. The additives contained in the cellulose acylate film 37 and the amounts thereof will be described later.

The saponification layer 12 has functions of initial antifogging property and long-term antifogging property. The saponification layer 12 is provided on one base surface (hereinafter referred to as a first base surface) 11a of the film base 11, and one film surface (hereinafter referred to as a first film surface) 10a of the antifogging film 10. Make. The saponified layer 12 comprises saponified cellulose acylate, in this example saponified TAC.

When the amount of acyl groups on the first film surface 10a is X, and the amount of acyl groups on one film surface (hereinafter referred to as the first film surface) 37a (see FIG. 2) of a cellulose acylate film 37 described later is Y. Further, the acyl group ratio obtained by X / Y is preferably small, for example, 0.7 or less. In the present embodiment, for example, 0.30. The smaller the acyl group ratio, the fewer the acyl groups on the first film surface 10a with respect to the cellulose acylate film 37, and in the saponification of the cellulose acylate film 37, more acyl groups were saponified to become hydroxy groups. Means. The smaller the acyl group ratio, the better the initial antifogging property. The acyl group ratio is more preferably in the range of 0.01 to 0.6. The amount of acyl groups on the other base surface (hereinafter referred to as the second base surface) 11 b of the film base 11 is equal to the amount of acyl groups Y on the first film surface 37 a of the cellulose acylate film 37.

The acyl group amount X and the acyl group amount Y are the total reflection measurement (ATR, Attenuated Total Reflection) method (hereinafter, referred to as FT-IR, Fourier Transform Infrared Spectroscopy, hereinafter referred to as FT-IR). This is determined as the spectral intensity of the acyl group determined by the ATR method. Specifically, the spectral intensity of the acyl group signal of the cellulose acylate is corrected (normalized) with the spectral intensity of the common signal of the cellulose polymer. In this embodiment, since TAC is used as the cellulose acylate, the acyl group is an acetyl group, and the signal of the acetyl group is 1210 cm ⁻¹ . The common signal of the cellulosic polymer is preferably 1030 cm ⁻¹ . Then, the spectrum intensity of the acyl group signal of the cellulose acylate obtained by the correction is determined as an acyl group amount X and an acyl group amount Y. Thus, the acyl group amount X and the acyl group amount Y are indices that are replaced by the number of acyl groups.

As is well known, the FT-IR ATR method is a method for obtaining a spectral intensity by injecting light into a measurement sample, and the obtained spectral intensity is not the surface of the measurement sample in a strict sense. When a diamond prism is used as a method in a general FT-IR ATR method and the measurement angle is 45 degrees, the light penetration depth from the surface of the measurement sample is about 2 to 3 μm. It is. Since the saponification layer 12 of this embodiment is very thin as will be described later, the reliability as the amount of acyl groups required for the saponification layer 12 decreases as the light penetration depth becomes deeper than 2 μm. Therefore, it is preferable to obtain the spectral intensity in the range of 2 μm depth from the first film surface 10 a as the acyl group amount X. In this embodiment, the light penetration depth is set to 2 μm, and the first film surface 10 a The spectral intensity in the range of 2 μm or less is defined as the acyl group amount X.

Similarly, it is preferable to obtain the spectrum intensity in the range of 2 μm in depth from the first film surface 37a (see FIG. 2) of the cellulose acylate film 37 as the acyl group amount Y, which is also the case in this embodiment.

The first film surface 10a preferably has a small contact angle (hereinafter referred to as a contact angle after 15 seconds) 15 seconds after dropping pure water, and is preferably 20 ° or less, for example. In this embodiment, it is 13 degrees, for example. The contact angle after 15 seconds is related to long-term antifogging properties. In addition, the contact angle is calculated in consideration of the time after dropping pure water, and the contact angle after 15 seconds, which is 15 seconds later, is used to more reliably evaluate the expression of long-term antifogging properties. be able to. The contact angle after 15 seconds is a characteristic showing the affinity of the film surface with water. In the measurement of the contact angle with respect to water, pure water permeates into a hydrophilic portion (hereinafter referred to as a hydrophilic film) formed in a film shape with a very small thickness on the surface of the saponified layer 12, or a hydrophilic film. Phenomena such as film components coming out from the inside occur with the passage of time after the addition of pure water, but by measuring 15 seconds after dropping, the film surface can be measured for long-term antifogging properties and corresponding hydrophilicity. I found it.

The contact angle after 15 seconds is preferably measured for the antifogging film 10 after humidity adjustment (humidity adjustment), and the humidity treatment conditions are a temperature range of 23 ° C. to 28 ° C. and relative humidity. Is preferably in the range of 55% or more and 65% or less, and the humidity conditioning time is more preferably 1 hour or more. In this embodiment, the humidity is adjusted for 1 hour in an atmosphere having a temperature of 25 ° C. and a relative humidity of 60%. This humidity adjustment treatment may adjust the humidity of the entire antifogging film 10, but it is sufficient to adjust the humidity of at least the saponified layer 12.

In the present embodiment, the antifogging film 10 is manufactured to be long as will be described later. For example, an adhesive layer is provided on the second base surface 11b and is cut into a sheet having a desired size. Provided. The pressure-sensitive adhesive layer is for attaching the antifogging film 10 to an object to be attached. In addition, although the anti-fogging film 10 of this example has the saponification layer 12 provided only in the 1st base surface 11a of the film base 11, it is not restricted to this. That is, the saponification layer 12 may be provided on the second base surface 11b in addition to the first base surface 11a. In this case, the pressure-sensitive adhesive layer is provided in such a manner that it is superimposed on one of the saponified layer 12 on the first base surface 11a and the saponified layer on the second base surface 11b.

The anti-fogging film manufacturing facility 30 shown in FIG. 2 is an example of an facility for continuously manufacturing the anti-fogging film 10. The anti-fogging film manufacturing facility 30 includes a delivery device 31, a saponification unit 32, a drying device 33, and a winder 34 in order from the upstream side in the conveyance direction of the cellulose acylate film 37. The cellulose acylate film 37 is a material of the anti-fogging film 10, and in this example, is made by a film forming apparatus (not shown) by a well-known solution film forming method. The cellulose acylate film 37 is made of cellulose acylate, and is the above-described TAC in this embodiment.

Details of the cellulose acylate will be described below. Cellulose acylate has a ratio in which the hydroxy group of cellulose is esterified with carboxylic acid, that is, the substitution degree of acyl group (hereinafter referred to as acyl substitution degree) satisfies all the conditions of the following formulas (1) to (3). What is satisfactory is particularly preferred. In (1) to (3), A and B are both acyl group substitution degrees, the acyl group in A is an acetyl group, and the acyl group in B has 3 to 22 carbon atoms.
2.4 ≦ A + B ≦ 3.0 (1)
0 ≦ A ≦ 3.0 (2)
0 ≦ B ≦ 2.9 (3)

The glucose unit constituting cellulose and having β-1,4 bonds has hydroxy groups at the 2nd, 3rd and 6th positions. Cellulose acylate is a polymer in which some or all of the hydroxy groups of cellulose are esterified, whereby the hydrogen of the hydroxy group is substituted with an acyl group having 2 or more carbon atoms. In addition, since the substitution degree is 1 when esterification of one hydroxy group in the glucose unit is 100%, in the case of cellulose acylate, the hydroxy groups at the 2nd, 3rd and 6th positions are 100 respectively. When% esterified, the degree of substitution is 3.

Here, the total acyl group substitution degree determined by “DS2 + DS3 + DS6” when the substitution degree of the acyl group at the 2-position in the glucose unit is DS2, the substitution degree of the acyl group at the 3-position is DS3, and the substitution degree of the acyl group at the 6-position is DS6. Is preferably 2.00 to 3.00, and is 2.86 in this embodiment.

There may be only one kind of acyl group, or two or more kinds. When there are two or more acyl groups, it is preferable that one of them is an acetyl group. DSA is the sum of the substitution degrees of the hydrogen groups of the hydroxy groups at the 2nd, 3rd and 6th positions with the acetyl group, and DSB is the sum of the substitution degrees with the acyl groups other than the acetyl groups at the 2nd, 3rd and 6th positions. In this case, the value of “DSA + DSB” is preferably 2.2 to 2.86, and particularly preferably 2.40 to 2.80. DSB is preferably 1.50 or more, and particularly preferably 1.7 or more. In DSB, 28% or more is preferably 6-position hydroxy group substitution, more preferably 30% or more, further preferably 31% or more, particularly preferably 32% or more substitution of 6-position hydroxy group. It is preferable that In addition, the value of “DSA + DSB” at the 6-position of cellulose acylate is preferably 0.75 or more, more preferably 0.80 or more, and particularly preferably 0.85 or more.

The acyl group having 2 or more carbon atoms may be an aliphatic group or an aryl group, and is not particularly limited. For example, there are cellulose alkylcarbonyl ester, alkenylcarbonyl ester, aromatic carbonyl ester, aromatic alkylcarbonyl ester, etc., and these may each further have a substituted group. Propionyl group, butanoyl group, pentanoyl group, hexanoyl group, octanoyl group, decanoyl group, dodecanoyl group, tridecanoyl group, tetradecanoyl group, hexadecanoyl group, octadecanoyl group, iso-butanoyl group, t-butanoyl group, cyclohexane Examples thereof include a carbonyl group, an oleoyl group, a benzoyl group, a naphthylcarbonyl group, and a cinnamoyl group. Among these, a propionyl group, a butanoyl group, a dodecanoyl group, an octadecanoyl group, a t-butanoyl group, an oleoyl group, a benzoyl group, a naphthylcarbonyl group, a cinnamoyl group, and the like are more preferable, and a propionyl group and a butanoyl group are particularly preferable.

In addition to cellulose acylate, the cellulose acylate film 37 may contain various additives such as a plasticizer, an ultraviolet absorber, a deterioration preventing agent, and fine particles for preventing sticking.

A plasticizer having a molecular weight of less than 500 causes a reduction in acyl groups during saponification described later, and causes a contact angle to increase after 15 seconds on the first film surface 10a. Therefore, in the cellulose acylate film 37, it is preferable that the mass of the plasticizer having a molecular weight of less than 500 is suppressed to at most 4%, that is, 4% or less with respect to the mass of the cellulose acylate. That is, when the mass of the cellulose acylate is MA and the mass of the plasticizer having a molecular weight of less than 500 is MB, the mass ratio (unit:%) obtained by (MB / MA) × 100 is 4% or less. Is preferred. When the mass ratio is 4% or less, acyl groups are more reliably reduced by saponification than when the mass ratio is larger than 4%. Further, when the mass ratio is 4% or less, it is possible to suppress the plasticizer having a molecular weight of less than 500 from being deposited on the first film surface 10a (see FIG. 1) as compared with the case where the mass ratio is greater than 4%. After 15 seconds, the contact angle is more reliably decreased, and the long-term antifogging property is more reliably exhibited. The mass ratio is more preferably in the range of 0% to 3%, further preferably in the range of 0% to 2%, and the smaller the better. The molecular weight is determined by a general chemical molecular weight determination method such as elemental analysis, liquid chromatography, gas chromatography, NMR (nuclear magnetic resonance), IR (Infrared Spectroscopy). In this embodiment, the molecular weight is obtained by comparison with a standard substance by gas chromatography. Examples of the plasticizer having a molecular weight of less than 500 include triphenyl phosphate (TPP) and biphenyl diphenyl phosphate (BDP).

The cellulose acylate film 37 preferably contains an ester oligomer having a repeating unit containing an ester bond of a dicarboxylic acid and a diol as a plasticizer and having a molecular weight in the range of 500 or more and 10,000 or less. The cellulose acylate film 37 also includes this. This molecular weight is different from the above-mentioned plasticizer with a molecular weight of less than 500, and has a molecular weight distribution, so the weight average molecular weight, number average molecular weight and terminal functional group weight are measured by GPC (Gel Permeation Chromatography). Or a number average molecular weight measurement method by osmotic pressure measurement, a viscosity average molecular weight by viscosity measurement, or the like. In this embodiment, it calculates | requires by the number average molecular weight measuring method by a terminal functional group measurement. By using an ester oligomer having a molecular weight in the range of 500 or more and 10,000 or less as a plasticizer, acyl groups are more reliably reduced in saponification described later. Further, by using the above ester oligomer as a plasticizer, precipitation on the first film surface 10a (see FIG. 1) is more reliably performed than when a general plasticizer monomer having a molecular weight of less than 500 is used. Thus, the contact angle after 15 seconds on the first film surface 10a tends to decrease, and the long-term antifogging property is more reliably exhibited. In addition, by using an ester oligomer having a molecular weight in the range of 500 or more and 10,000 or less as a plasticizer, the antifogging film 10 is improved in handleability such as sticking to and pasting on an object to be pasted. The larger the molecular weight of the SL oligomer, the longer the antifogging property, and the smaller the molecular weight, the better the compatibility with the cellulose acylate. Therefore, the molecular weight of the ester oligomer is more preferably in the range of molecular weight 700 to 5000, more preferably 900 to 3000. It is further preferable to be within the range.

The above dicarboxylic acid is more preferably an aliphatic dicarboxylic acid having a carbon number in the range of 2 to 10. The diol is more preferably an aliphatic diol having 2 to 10 carbon atoms. This is because by using an aliphatic dicarboxylic acid and an aliphatic diol, flexibility can be imparted to the anti-fogging film 10, and it is difficult to generate a decomposition product that inhibits the reduction of the contact angle after 15 seconds described later. It is. Examples of the aliphatic carboxylic acid include malonic acid, succinic acid, glutaric acid, adipic acid, sebacic acid, azelaic acid, cyclohexanedicarboxylic acid, maleic acid, fumaric acid and the like. Aliphatic diols include ethanediol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,3-butanediol, 2-methyl-1,3-propanediol, 1, 4-butanediol, 1,5-pentanediol, 2,2-dimethyl-1,3-propanediol (neopentyl glycol), 1,4-hexanediol, 1,4-cyclohexanediol, 1,4-cyclohexanedi Methanol etc. are mentioned. In this embodiment, an ester oligomer composed of adipic acid and ethanediol (the number average molecular weight determined by the terminal hydroxyl group determination method is about 1000) is used as the ester.

The sending machine 31 sends out the long cellulose acylate film 37 continuously. The cellulose acylate film 37 is set in the delivery machine 31 while being wound around the winding core 38 in a roll shape. By rotating the winding core 38, the cellulose acylate film 37 is continuously fed out.

The saponification unit 32 is for continuously saponifying the cellulose acylate film 37 into the antifogging film 10. The saponification unit 32 includes a coating device 41, an infrared heater 42, a cleaning device 43, and a roller 44. A plurality of rollers 44 are provided, but only one is shown in FIG. The roller 44 supports the cellulose acylate film 37 from below on the peripheral surface, and conveys the cellulose acylate film 37 by rotating around the rotation axis.

The coating device 41 is for applying the saponification solution 47 to the first film surface 37 a of the cellulose acylate film 37. The coating device 41 continuously flows out the supplied saponification solution 47 from the outflow port 41 a facing the first film surface 37 a of the cellulose acylate film 37. The saponification solution 47 is continuously applied to the first film surface 37a by the application device 41 continuously flowing out the saponification solution 47 to the cellulose acylate film 37 being conveyed (saponification solution application step). By applying the saponifying solution 47 by coating, the contact angle after 15 seconds can be surely lowered as compared with the method of applying by immersing, so that the certainty of long-term antifogging is increased.

The saponification solution 47 is for saponifying the first film surface 37a side of the cellulose acylate film 37, thereby forming the saponification layer 12 (see FIG. 1), and contains alkali and water. The alkali is potassium hydroxide (KOH) in the present embodiment, but is not limited to this, and may be sodium hydroxide (NaOH). The first film surface 37a side of the cellulose acylate film 37 is saponified by being coated with an alkali, whereby the acyl group of the cellulose acylate becomes a hydroxy group and the acyl group decreases. In this example, the saponification solution 47 contains alcohol having 2 to 3 carbon atoms in addition to alkali and water, and the coating device 41 applies the saponification solution 47 to apply the first film surface 37a. Alcohol is also applied to (alcohol application step). The alcohol is used to promote alkali soaking into the cellulose acylate film 37. As the alcohol having 2 to 3 carbon atoms, isopropyl alcohol is particularly preferable, and isopropyl alcohol is also used in this embodiment.

In this example, by adding alcohol to the saponification liquid 47, the saponification liquid application process includes the alcohol application process, but the present invention is not limited to this mode. For example, a method of sequentially applying an alcohol and an aqueous solution of an alkali, that is, an alcohol application step and a saponification solution application step may be independent. In this case, it is more preferable to apply a saponification solution after application of alcohol.

Alcohol, to the first film surface 37a, at least 17g amount per area 1 m ² of the first film surface 37a, that is, 17g / m ² or more coating amount is applied. The greater the amount of alcohol applied, the smaller the contact angle after 15 seconds. The coating amount of the alcohol is more preferably it is preferably in the range of 17 g / m ² or more 39.6 g / m ² or less, in the range of 22 g / m ² or more 39.6 g / m ² or less, 33 More preferably, it is in the range of not less than 4 g / m ^{2 and not} more than 39.6 g / m ² .

The alkali is applied to the first film surface 37a in an amount of at least 0.3 g per 1 m ² area of the first film surface 37a, that is, an application amount of 0.3 g / m ² or more. As a result, the alkali is surely soaked quickly into the cellulose acylate film 37. The amount of alkali alcohol applied is preferably in the range of 0.3 g / m ^{2 to} 1.3 g / m ^2, preferably in the range of 0.6 g / m ^{2 to} 1.3 g / m ^2. It is more preferable that it is in the range of 0.7 g / m ² or more and 1.3 g / m ² or less.

The infrared heater 42 is for holding the cellulose acylate film 37 to keep the temperature within a temperature range described below for a time described below. The infrared heater 42 is provided so that the emission surface for emitting infrared rays faces the cellulose acylate film 37 being conveyed. The infrared heater 42 may be disposed so as to face the first film surface 37a on which the coating film 48 formed from the saponification solution 47 is formed. However, as in the present embodiment shown in FIG. The first film surface 37a is preferably arranged so as to face the second film surface 37a which is the film surface opposite to the first film surface 37a. This is because the cellulose acylate film 37 can be heated while suppressing the evaporation of alcohol contained in the coating film 48. By heating the cellulose acylate film 37 while suppressing the evaporation of alcohol, the alkali soaks more reliably and more efficiently from the first film surface 37a side.

Instead of the infrared heater 42, a blowing type blower for blowing heated gas to the cellulose acylate film 37, or a chamber for supplying heated gas to the chamber by surrounding the conveyance path of the cellulose acylate film 37 with a chamber. An air blower or the like may be used. Moreover, these air blowers may be used in combination with the infrared heater 42. In the case of using a blowing type blower, it is preferable to spray the second film surface 37b from the viewpoint of further suppressing the evaporation of alcohol from the coating film 48. From the viewpoint of more reliably suppressing the evaporation of alcohol from the coating film 48, the chamber type blower is preferable to the spray type blower, and the infrared heater 42 is more preferable than the chamber type blower.

If the thickness T12 (see FIG. 1) of the saponified layer 12 is too small, the initial antifogging property is hardly exhibited, and if it is too large, the long-term antifogging property is hardly exhibited. Therefore, in order to achieve both initial antifogging properties and long-term antifogging properties, the first film surface 37a is heated to a temperature of 40 ° C. or higher and 80 ° C. or lower by heating with the infrared heater 42 for a time of 20 seconds or longer and 120 seconds or shorter. And hold (temperature holding step). By maintaining the temperature at 40 ° C. or higher, saponification proceeds more quickly than when the temperature is lower than 40 ° C., and the saponified layer 12 having a larger thickness T12 is formed, so that the initial antifogging property is surely exhibited. . By maintaining the temperature at 80 ° C. or lower, the saponified layer 12 is reliably formed in a state where the evaporation of alcohol is reliably suppressed as compared with the case where the temperature is higher than 80 ° C., and the saponified layer 12 having a small thickness T12 is formed. In addition, long-term antifogging properties are surely exhibited. The temperature to be held is more preferably in the range of 40 ° C. or higher and 70 ° C. or lower, and further preferably in the range of 50 ° C. or higher and 70 ° C. or lower. In addition, the film surface hold | maintained in the said temperature range may be at least any one of the 1st film surface 37a and the 2nd film surface 37b.

The time for maintaining the above temperature range is 20 seconds or more and 120 seconds or less. By setting it to 20 seconds or more, saponification proceeds more rapidly than in the case of less than 20 seconds, and the saponification layer 12 having a larger thickness T12 (see FIG. 1) is formed. It expresses surely. By setting it within 120 seconds, the saponified layer 12 is formed with a thinner thickness T12 (see FIG. 1) than when it is longer than 120 seconds, and thus long-term antifogging properties are reliably exhibited. Further, as shown in FIG. 3, the time for holding in the above temperature range is also related to the contact angle after 15 seconds, and the contact angle after 15 seconds decreases with the passage of time to hold the temperature, Then it begins to increase. The first film surface 10a having a small contact angle after 15 seconds can be formed by keeping the temperature range within the above temperature range from 20 seconds to 120 seconds. From this viewpoint, the long-term antifogging property is ensured. Expressed in The time for maintaining in the above temperature range is more preferably 30 seconds or more and 100 seconds or less, and further preferably 30 seconds or more and 50 seconds or less.

In addition, thickness T12 of the saponification layer 12 is calculated | required with the following method in this embodiment from the obtained anti-fogging film 10. FIG. A sample sampled from the antifogging film 10 is immersed in dichloromethane for 24 hours. The sample remaining undissolved by this immersion is dried, and the thickness of the dried sample is measured three times. The average of the three measured values is defined as thickness T12.

The cleaning device 43 is for stopping saponification by cleaning the cellulose acylate film 37. The cleaning device 43 includes a spray type cleaning machine that sprays water on the first film surface 37 a side on which the coating film 48 is formed. The alkali is quickly removed from the cellulose acylate film 37 by spraying water. By removing this alkali, saponification is stopped. Thereby, the thickness T12 of the saponified layer 12 is not excessively increased, and the long-term antifogging property is more reliably exhibited. In place of the spray type washing machine, an immersion type washing machine that guides the cellulose acylate film 37 to a container containing water and immerses it in water may be used. Therefore, a spray type washing machine is preferable, and a larger flow rate and flow rate of sprayed water are more preferable.

Instead of the cleaning device 43, an acid supply machine that supplies acid to the coating film 48 may be used. Examples of the acid supply device include a spray-type supply device that sprays an aqueous solution of an acid toward the first film surface 37a on which the coating film 48 is formed. The acid is for neutralizing the alkali, and for example, hydrochloric acid, sulfuric acid and the like are preferable. The saponification is stopped by neutralization, whereby the thickness T12 of the saponified layer 12 is not excessively increased, and the long-term antifogging property is more reliably exhibited.

The saponified layer 12 is formed on the cellulose acylate film 37 that has passed through the cleaning device 43, and this cellulose acylate film 37 is guided to the drying device 33 and dried. In the present embodiment, a chamber-type drying device that surrounds the conveyance path with a chamber and supplies heated gas to the chamber is used as the drying device, but is not particularly limited. By this drying, the contained water evaporates, and the antifogging film 10 is obtained in a long length. The antifogging film 10 is guided to the winder 34 and wound around the set core 49 in a roll shape.

In the above example, only the first film surface 37a side of the cellulose acylate film 37 is saponified, but in addition to the first film surface 37a side, the second film surface 37b side may be saponified. Also in this case, it is preferable to perform the above-described alcohol application step, saponification solution application step, and temperature holding step.

[Example 1] to [Example 11]
A cellulose acylate film 37 was formed from the dope by a solution casting method. The dope was prepared by putting a composition having the following formulation into a sealed container and completely dissolving it by stirring while keeping it at 40 ° C. under normal pressure. The raw material for TAC is linter. TAC has an acyl group substitution degree of 2.86 and a viscosity average polymerization degree of 320. The fine particles are R972 (manufactured by Nippon Aerosil Co., Ltd.). The fine particles were dispersed by mixing in advance in a solution in which TAC was dissolved in a solvent that was a mixture of dichloromethane and methanol. And this dispersion liquid was thrown into said airtight container, and it was set as the composition of the following prescription. After standing, this liquid was filtered using a filter paper (No. 63, manufactured by Advantech Toyo Co., Ltd.) while being kept at 30 ° C., and subjected to a defoaming operation, to obtain a dope.

TAC 100 parts by mass Dichloromethane 635 parts by mass Methanol 125 parts by mass Plasticizer 15 parts by mass Fine particles 1.3 parts by mass

As the plasticizer, an ester oligomer based on adipic acid and ethanediol or triphenyl phosphate (molecular weight: 325) was used. The molecular weight of the ester oligomer was about 1000 as the number average molecular weight determined by the terminal hydroxyl group quantification method. When an ester oligomer is used, “A” is described in the “Type” column of “Plasticizer” in Table 1, and “B” is described when triphenyl phosphate is used. The mass of the plasticizer relative to the mass of cellulose acylate is shown in the “mass ratio” column of “plasticizer” in Table 1.

The dope whose temperature was adjusted to 30 ° C. was cast on the support. The support is an endless belt made of stainless steel. The cast film is dried by applying hot air of 100 ° C. immediately after the formation, and 120 seconds after the formation, the cast film is peeled off from the support with a peeling tension of 150 N / m, and cellulose acylate Film 37 was formed. The temperature of the support at the peeling position was 10 ° C. The residual solvent amount of the cast film at the time of peeling was 100% by mass.

The peeled cellulose acylate film 37 was dried while being transported in a state where the tension in the longitudinal direction was set to 100 N / m by a number of rolls arranged in the transport path. Drying was carried out by transporting the first drying zone set at 80 ° C. for 5 minutes and further transporting it for 10 minutes in the second drying zone set at 120 ° C. After drying, the cellulose acylate film 37 was rolled up to obtain a film roll. The width of the cellulose acylate film 37 was 1.5 m, and the winding length in the film roll was 2000 m. The residual solvent amount of the cellulose acylate film 37 at the time of winding was 0.3%.

From the obtained cellulose acylate film 37, 11 types of anti-fogging films 10 were produced by an anti-fogging film production facility 30 and designated as Examples 1 to 11. Each anti-fogging film 10 was specifically manufactured by the following method. The cellulose acylate film 37 was sent out by the feeder 31 and conveyed, and the saponification solution 47 was applied to the first film surface 37 a of the cellulose acylate film 37 by the coating device 41. In this way, when the saponification solution 47 is applied by application, “application” is described in the “method” column of “saponification” in Table 1. The saponification solution 47 contained isopropyl alcohol. The “application amount” column of “saponification” in Table 1 is the application amount of the saponification solution 47.

As the saponification solution 47, the following three types of type A, type B, and type C are prepared, and “A”, “B”, and “C” are described in the “saponification solution” column of Table 1, respectively. In the following formulation,% is a percentage by mass.

<Type A saponification solution>
Potassium hydroxide (KOH) 3.3%
Isopropyl alcohol 88.0%
Water 3.6%
Propylene glycol 5.0%
Surfactant 0.1%

<Type B saponification solution>
Potassium hydroxide (KOH) 9.7%
Isopropyl alcohol 60.0%
Water 10.5%
Propylene glycol 14.8%
Surfactant 5.0%

<Type C saponification solution>
Potassium hydroxide (KOH) 1.9%
Isopropyl alcohol 92.5%
Water 2.1%
Propylene glycol 3.0%
Surfactant 0.5%

The cellulose acylate film 37 coated with the saponification solution 47 is heated by the infrared heater 42, and the first film surface 37a is held at the temperature shown in the "Temperature" column of Table 1 for the time shown in "Temperature holding time". did. For each of the long antifogging films 10 thus obtained, the thickness T10, the contact angle after 15 seconds, and the acyl group ratio were determined. Each method of obtaining the contact angle after 15 seconds and the acyl group ratio is as described above. The thickness T10 is an average value of values measured at intervals of 0.5 mm in the width direction using a contact-type thickness meter. These results are shown in Table 1. The contact angle after 15 seconds is described in the “Contact angle” column of Table 1.

Each initial antifogging property and long-term antifogging property of each obtained antifogging film 10 were evaluated by the following methods and standards. Each evaluation result is shown in Table 1.

(1) Initial antifogging property The antifogging film 10 was affixed on the glass plate cooled to the temperature range of 10 degreeC or more and 15 degrees C or less, and cloudiness was evaluated in the room | chamber interior of 25 degreeC and 60% of relative humidity. Evaluation was made based on the following criteria based on the time from the past application of the entire anti-fogging film 10 to a glass plate using a colorless and transparent sheet-type double-sided adhesive tape until cloudiness. In addition, you may affix the anti-fogging film 10 to a glass plate by the method of apply | coating an adhesive to either one of a glass plate and the anti-fogging film 10 instead of using a double-sided adhesive tape. It became cloudy when things could not be seen through the glass plate. A and B are acceptable levels, and C and D are unacceptable levels.
A: It is 10 minutes or more.
B: 5 minutes or more and less than 10 minutes.
C: 1 minute or more and less than 5 minutes.
D: Less than 1 minute.

(2) Long-term antifogging property The door was removed from the refrigerator, glass was attached as a substitute for the door, and the antifogging film 10 was affixed to the surface of this glass. The room where the refrigerator was placed was kept at 25 ° C. and 60% relative humidity. The anti-fogging film 2 hours after pasting was visually observed and evaluated according to the following criteria. A is a pass level, and B and C are fail levels.
A: Water droplets were not confirmed on the antifogging film.
B: Although the inside of the refrigerator was visible, water droplets were confirmed on the antifogging film 10.
C: Cloudy and the inside of the refrigerator could not be seen.

[Comparative Example 1] to [Comparative Example 13]
Thirteen types of anti-fogging films were produced by changing the application method of the saponifying solution 47 and the type of the saponifying solution 47 to the conditions shown in Table 1 to obtain Comparative Examples 1 to 13. As the saponification solution 47, the following type D saponification solution 47 is also prepared, and when this is used, “D” is described in the “saponification solution” column of Table 1. When the cellulose acylate film 37 is soaked in the saponification solution 47 and the saponification solution 47 is applied to the cellulose acylate film 37, “Dip” is written in the “Method” column of “Saponification” in Table 1. In this case, since the application amount of the saponification solution 47, the application amount of alkali, and the application amount of alcohol cannot be detected, the “application amount” column, “alkaline application amount” column, and “alcohol application amount” column Write “-”.

<Type D saponification solution>
Potassium hydroxide (KOH) 20%
80% water

About the obtained antifogging film, thickness T10, contact angle after 15 seconds, and acyl group ratio were determined, respectively, and the initial antifogging property and long-term antifogging property were evaluated by the same method and standard as in the examples. . These results are shown in Table 1.

Claims

In the method for producing an antifogging film by producing an antifogging film by saponifying a cellulose acylate film with an alkali,
An alcohol application step of applying an alcohol having 2 to 3 carbon atoms on one film surface of the cellulose acylate film in an amount of at least 17 g per 1 m 2 ;
A saponification solution application step of applying a saponification solution containing the alkali and water to the one film surface;
A temperature maintaining step of maintaining the temperature of the film surface within a range of 40 ° C. or more and 80 ° C. or less for a time of 20 seconds or more and 120 seconds or less by heating the cellulose acylate film coated with the saponification solution;
A method for producing an antifogging film having
The method for producing an anti-fogging film according to claim 1, wherein the saponification solution application step includes the alcohol application step, and the saponification solution containing the alcohol is applied.
The method for producing an antifogging film according to claim 1 or 2, wherein the amount of the alkali applied to the one film surface is at least 0.3 g per 1 m 2 .
As the next step of the temperature holding step, it has either one of a washing step for washing the cellulose acylate film and a neutralization step for neutralizing the alkali contained in the cellulose acylate film with an acid,
The method for producing an antifogging film according to claim 1 or 2, wherein saponification is stopped by washing or neutralization.
The method for producing an anti-fogging film according to claim 1 or 2, wherein in the temperature holding step, the cellulose acylate film is heated by an infrared heater that emits infrared rays.
The said infrared heater is a manufacturing method of the anti-fogging film of Claim 5 which irradiates the said infrared rays to the other film surface of the said cellulose acylate film.
The anti-fogging film according to claim 1 or 2, wherein the cellulose acylate film used in the saponification solution coating step has a mass of a plasticizer having a molecular weight of less than 500 of at most 4% with respect to the mass of the cellulose acylate. A method for producing a film.
The cellulose acylate film to be subjected to the saponification solution coating step is
The method for producing an antifogging film according to claim 1 or 2, comprising an ester oligomer having a repeating unit containing an ester bond of a dicarboxylic acid and a diol and having a molecular weight of 500 or more and 10,000 or less as a plasticizer.
9. The prevention according to claim 8, wherein the dicarboxylic acid is an aliphatic dicarboxylic acid having a carbon number in the range of 2 to 10, and the diol is an aliphatic diol having a carbon number in the range of 2 to 10. A method for producing a cloudy film.