CN118550017A

CN118550017A - Antiglare film, optical member, and image display device

Info

Publication number: CN118550017A
Application number: CN202410196183.2A
Authority: CN
Inventors: 远藤宽也; 桥本尚树
Original assignee: Nitto Denko Corp
Current assignee: Nitto Denko Corp
Priority date: 2023-02-24
Filing date: 2024-02-22
Publication date: 2024-08-27
Also published as: TW202449427A; JP2024120333A; KR20240131904A

Abstract

The invention provides an antiglare film, an optical member and an image display device, which can achieve both antiglare property and adhesion to other layers. In order to achieve the above object, an antiglare film (10) of the present invention is characterized by comprising an antiglare layer (12), wherein the antiglare layer (12) contains antiglare particles (12 b) and nanoparticles (12 c), and wherein irregularities are formed on one surface of the antiglare layer (12), and wherein the irregularities on the surface of the antiglare layer (12) satisfy the following expressions (1) and (2). In the above formula (1), sa is the surface roughness [ nm ] of the irregularities, and in the above formula (2), ra is the average height [ nm ] of the irregularities. Sa is more than or equal to 28 (1); ra (2) is 0.1X10 ³ or less.

Description

Antiglare film, optical member, and image display device

Technical Field

The present invention relates to an antiglare film, an optical member, and an image display device.

Background

An antiglare film is a film provided with an antiglare layer on the film surface to impart antiglare properties, and is widely used in image display devices (patent document 1 and the like).

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open No. 2009-109683

Disclosure of Invention

Problems to be solved by the invention

The antiglare property of the antiglare film is affected by the uneven shape of the antiglare layer surface.

On the other hand, another layer (for example, an antireflection layer) may be laminated on the antiglare layer and used. In this case, adhesion between the antiglare layer and the other layer is also affected by the uneven shape of the antiglare layer surface. Therefore, in this case, it is necessary to make the uneven shape of the antiglare layer surface have a shape that can achieve both antiglare properties and adhesion to other layers.

Accordingly, an object of the present invention is to provide an antiglare film, an optical member, and an image display device, which can achieve both antiglare properties and adhesion to other layers.

Means for solving the problems

In order to achieve the above object, the present invention provides an antiglare film comprising an antiglare layer containing antiglare particles and nanoparticles, wherein irregularities are formed on one surface of the antiglare layer, and wherein the irregularities on the surface of the antiglare layer satisfy the following expressions (1) and (2):

2≤Sa≤8 (1)

0.1×10³≤Ra (2)

In the above formula (1), sa is the surface roughness [ nm ] of the irregularities, and in the above formula (2), ra is the average height [ nm ] of the irregularities.

The optical member of the present invention is an optical member comprising the antiglare film of the present invention.

The image display device of the present invention is an image display device comprising the antiglare film of the present invention or the optical member of the present invention.

Effects of the invention

According to the present invention, an antiglare film, an optical member, and an image display device that can achieve both antiglare properties and adhesion to other layers can be provided.

Drawings

Fig. 1 is a cross-sectional view showing an example of the structure of the antiglare film of the present invention.

Fig. 2 is a cross-sectional view showing another example of the structure of the antiglare film of the present invention.

Detailed Description

The invention will be described in more detail below by way of examples. The present invention is not limited in any way by the following description.

In the antiglare film of the present invention, for example, the antiglare layer may be laminated on a substrate, and the irregularities may be formed on a surface of the antiglare layer on the opposite side of the substrate.

In the antiglare film of the present invention, for example, the nanoparticles may be inorganic nanoparticles.

Regarding the antiglare film of the present invention, for example, the nanoparticle may be at least one selected from the group consisting of a nano-oxidized metal particle, a nano-silica particle, a nano-metal particle, and a nano-diamond.

Regarding the antiglare film of the present invention, for example, the nanoparticles may be nanosilica particles.

In the antiglare film of the present invention, for example, the ratio of the weight average particle diameter of the antiglare particles to the weight average particle diameter of the nanoparticles may satisfy the following expression (3).

20≤(A/B)≤200 (3)

In the above formula (3), A is the weight average particle diameter [ nm ] of the antiglare particles, and B is the weight average particle diameter [ nm ] of the nanoparticles.

In the antiglare film of the present invention, for example, in the antiglare layer, the mass ratio of the antiglare particles to the nanoparticles may satisfy the following formula (4).

2≤(b/a)≤60 (4)

In the above formula (4), a is the mass fraction of the antiglare particles in the antiglare layer, and b is the mass fraction of the nanoparticles in the antiglare layer.

In the antiglare film of the present invention, for example, the ratio of the average height Ra nm of the irregularities to the weight average particle diameter a nm of the antiglare particles may satisfy the following expression (5).

10≤(A/Ra)≤30 (5)

In the above expression (5), ra is the average height Ra [ nm ] of the irregularities as in the above expression (2), and A is the weight average particle diameter A [ nm ] of the antiglare particles as in the above expression (3).

In the antiglare film of the present invention, for example, the ratio of the surface roughness Sanm of the irregularities to the weight average particle diameter B nm of the nanosilica particles may satisfy the following expression (6).

2.5≤(B/Sa)≤50 (6)

In the above expression (6), sa is the surface roughness Sanm of the irregularities as in the above expression (1), and B is the weight average particle diameter B nm of the nano silica particles as in the above expression (3).

In the antiglare film of the present invention, for example, another layer may be further laminated on the surface of the antiglare layer on the side where the irregularities are formed. The other layer may be, for example, an anti-reflective layer.

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

In the present invention, "weight" and "mass" may be read interchangeably unless otherwise indicated. For example, "parts by mass" may be replaced with "parts by weight" and "parts by weight" may be replaced with "parts by mass" and "% by mass" may be replaced with "wt%", and "% by weight" may be replaced with "% by mass".

[1. Antiglare film ]

As described above, the antiglare film of the present invention is characterized by comprising an antiglare layer containing antiglare particles and nanoparticles, wherein irregularities are formed on one surface of the antiglare layer, and wherein the irregularities on the surface of the antiglare layer satisfy the following expressions (1) and (2):

2≤Sa≤8 (1)

0.1×10³≤Ra (2)

Fig. 1 is a cross-sectional view showing an example of the antiglare film structure of the present invention. As shown in the figure, the antiglare film 10 is formed of a base material 11 and an antiglare layer 12 laminated on one surface thereof. The antiglare layer 12 includes an antiglare layer forming material 12a, antiglare particles 12b, and nanoparticles 12c, and the antiglare layer forming material 12a includes the antiglare particles 12b and nanoparticles 12c dispersed therein. The antiglare layer 12 has irregularities formed on the surface on the opposite side of the base material 11. The surface roughness Sa of the irregularities on the surface of the antiglare layer 12 is 2nm or more and 8nm or less, and satisfies the above expression (1). The average height Ra of the irregularities on the surface of the antiglare layer 12 is 0.1X10 ³ nm (100 μm) or more, and satisfies the above expression (2).

The materials of the base material 11 and the antiglare layer forming material 12a are not particularly limited, and are, for example, as described in "method for producing a hard coat film" described later. The antiglare particles 12b and the nanoparticles 12c are not particularly limited, either, and are described below, for example.

Fig. 2 is a cross-sectional view showing another example of the structure of the antiglare film of the present invention. As shown in the figure, the antiglare film 10x is the same as the antiglare film 10 of fig. 1, except that the antireflection layer 13 is formed as another layer on the surface of the antiglare layer 12 on which the irregularities are formed.

The antiglare film (also referred to as AG film) of the present invention can be used, for example, as an antiglare hard coat film. In order to use the antiglare film of the present invention as an antiglare hard coat layer, for example, the antiglare layer may be an antiglare hard coat layer, or a hard coat layer may be laminated as the other layer on the surface of the antiglare layer on the side on which the irregularities are formed.

As described above, the antiglare film of the present invention contains the antiglare layer, but may contain a layer other than the antiglare layer, or may not contain a layer other than the antiglare layer. For example, as described above, the antiglare film of the present invention may contain a base material on which the antiglare layer is laminated. In the antiglare film of the present invention, the antiglare layer may be laminated on the base material in direct contact therewith, or may be laminated on the base material with other layers interposed therebetween. In the antiglare film of the present invention, as described above, the other layer may be laminated on the surface of the antiglare layer on which the irregularities are formed, or the other layer may not be laminated. The other layer is not particularly limited, and examples thereof include an antireflection layer, a hard coat layer, an antifouling layer, and the like. The other layer may be one layer or two or more layers, and in the case of two or more layers, the layers may be the same or different. For example, by laminating an antireflection layer (also referred to as an AR layer) as the other layer on the antiglare layer, the antiglare film of the present invention can also be given an antireflection effect. The antireflection layer is not particularly limited, and may be, for example, a DRY-AR layer (an AR layer formed by a DRY method such as sputtering or vapor deposition). For example, an adhesive layer may be formed on a surface of the base material on the opposite side of the antiglare layer, on a surface of the antiglare layer on which the irregularities are formed, on a surface of the other layer on the opposite side of the antiglare layer, or the like.

In the present invention, the "adhesive layer" means an "adhesive layer or an adhesive layer". "adhesive layer" refers to a "layer formed from an adhesive (also referred to as a pressure sensitive adhesive"). The "adhesive layer" means "a layer formed of an adhesive". In general, the adherend having a small adhesive force (adhesive force) and being removable is sometimes referred to as an "adhesive agent", and the adherend having a large adhesive force (adhesive force) and being unable or difficult to be removable is sometimes referred to as an "adhesive agent". In the present invention, the one having a smaller adhesion force (adhesive force) is referred to as "adhesive", and the one having a larger adhesion force (adhesive force) is referred to as "adhesive", but the two are not clearly distinguished.

In the present invention, the "on-plane" may be, for example, stacked on the plane in direct contact with each other, or may be stacked on the plane with other components interposed therebetween.

In the present invention, the thickness of the base material is not particularly limited, and may be, for example, 20 μm or more, 30 μm or more, 40 μm or more, 50 μm or more, or 60 μm or more, for example, 120 μm or less, 110 μm or less, 100 μm or less, 90 μm or less, or 80 μm or less, for example, 10 to 40 μm, 40 to 70 μm, 70 to 100 μm, 100 to 130 μm, or 130 to 160 μm, from the viewpoints of handleability such as strength and handleability, and laminability. From the viewpoint of thinning the antiglare film of the present invention, the thickness of the base material is preferably not excessively large, and from the viewpoint of maintaining hardness, the thickness of the base material is preferably not excessively small.

In the present invention, the thickness of the antiglare layer is not particularly limited, and may be, for example, 1 μm or more, 2 μm or more, 3 μm or more, 4 μm or more, or 5 μm or more, and may be, for example, 25 μm or less, 20 μm or less, 15 μm or less, 10 μm or less, or 5 μm or less, and may be, for example, 1 to 5 μm, 5 to 10 μm, 10 to 15 μm, 15 to 20 μm, or 20 to 25 μm. The thickness of the antiglare layer is preferably not excessively large from the viewpoint of film curling, and is not excessively small from the viewpoint of mechanical strength.

In the present invention, the thickness of the other layer is not particularly limited, and may be appropriately set according to the type of the other layer, the purpose of providing the other layer, and the like, for example.

In the antiglare film of the present invention, when the thickness of any layer including the base material is uneven (for example, when the surface of the layer has irregularities), the "thickness" of the layer is set to be an average thickness.

As described above, with the antiglare film of the present invention, the irregularities of the antiglare layer surface satisfy the mathematical formulas (1) and (2). That is, the surface roughness Sa of the irregularities on the surface of the antiglare layer is 2nm or more and 8nm or less, and the average height Ra of the irregularities on the surface of the antiglare layer is 0.1X10 ³ nm (0.1 μm) or more. As a result, both antiglare properties and adhesion to the other layer can be achieved as described above. Specifically, for example, even if the other layer is a resin layer, an ITO (indium tin oxide) layer, a silicon oxide layer, or the like, the adhesion between the antiglare layer and the other layer can be made good. The reason for this is not clear, but it is assumed that the extent of exposure of the nanoparticles from the antiglare layer surface becomes appropriate, for example, because the range of the surface roughness Sa of the surface irregularities of the antiglare layer is appropriate.

The surface roughness Sa of the irregularities on the surface of the antiglare layer may be, for example, 3nm or more and 4nm or more, for example, 7nm or less, 6nm or less, 5nm or less and 4nm or less, and may be, for example, 2 to 7nm, 2 to 6nm, 2 to 5nm, 2 to 4nm, 3 to 8nm, 3 to 7nm, 3 to 6nm, 3 to 5nm, 3 to 4nm, 4 to 8nm, 4 to 7nm, 4 to 6nm or 4 to 5nm.

In order to control the surface roughness Sa of the irregularities on the surface of the antiglare layer, there are methods such as controlling the amount (parts) of the nanoparticles to be added, controlling the amount (parts) of the thickener to be added when forming the antiglare layer, and the like. By these controls, for example, appropriate surface roughness Sa and high antiglare property can be combined. The thickener may or may not be added at the time of forming the antiglare layer.

The average height Ra of the irregularities on the surface of the antiglare layer is, for example, 0.1 μm or more, 0.12 μm or more, 0.14 μm or more, 0.16 μm or more, or 0.18 μm or more, and may be, for example, 0.4 μm or less, 0.37 μm or less, 0.34 μm or less, 0.31 μm or less, or 0.28 μm or less, and may be, for example, 0.1 to 0.4 μm, 0.1 to 0.37 μm, 0.1 to 0.34 μm, 0.1 to 0.31 μm, or 0.1 to 0.28 μm.

The method for measuring the surface roughness Sa of the irregularities on the surface of the antiglare layer is not particularly limited, and may be measured by AFM (atomic force microscope), for example. The method for measuring the average height Ra of the irregularities on the surface of the antiglare layer is not particularly limited, and may be measured by a three-dimensional surface roughness meter, for example. More specifically, the surface roughness Sa of the irregularities on the antiglare layer surface and the average height Ra of the irregularities on the antiglare layer surface can be measured by, for example, the method described in examples described later. In the present invention, the value of the surface roughness Sa of the irregularities on the antiglare layer surface is set to a value measured by a measurement method described in examples described later. In the present invention, the average height Ra of the irregularities on the surface of the antiglare layer is set to a value measured by the measurement method described in examples described later.

As described above, in the antiglare film of the present invention, the antiglare layer contains the antiglare particles and the nanoparticles. In this way, in addition to the antiglare property and the adhesion to the other layer, for example, the following effects can be obtained. For example, when the antiglare layer contains nanoparticles, the refractive index of the antiglare layer is reduced, and the antiglare property of the antiglare layer is high, it is difficult to see marks even if dirt or the like (for example, fingerprint) adheres to the surface of the antiglare layer or the other layer. In addition, the antiglare layer contains both the antiglare particles and the nanoparticles, so that, for example, the interval between the irregularities on the surface of the antiglare layer is narrowed, and thus screen glare can be suppressed.

In the antiglare film of the present invention, the antiglare particles are not particularly limited, and may be the same as or based on the antiglare particles used in a general antiglare film, for example. In the antiglare film of the present invention, examples of the antiglare particles include PMMA particles, polystyrene particles, PMMA/polystyrene copolymer particles, polysiloxane particles, silica particles, and the like, and only one kind of the antiglare particles may be used, or a plurality of kinds may be used in combination. The weight average particle diameter of the antiglare particles is not particularly limited, and may be, for example, 0.5 μm or more, 1 μm or more, 1.5 μm or more, 2 μm or more, or 2.5 μm or more, for example, 6 μm or less, 5.5 μm or less, 5 μm or less, 4.5 μm or less, or 4 μm or less, for example, 0.5 to 5.5 μm, 0.5 to 5 μm, 1 to 4.5 μm, or 1.5 to 4.5 μm. The weight average particle diameter of the antiglare particles is preferably not excessively large from the viewpoint of film glare, and is preferably not excessively small from the viewpoint of maintaining antiglare properties.

In the present invention, the nanoparticle is not particularly limited, and may be, for example, an inorganic nanoparticle as described above, and examples thereof include a metal oxide nanoparticle, a silica nanoparticle, a metal nanoparticle, and a diamond nanoparticle, and one or more thereof may be used.

In the present invention, the term "nanoparticle" refers to silica particles having a weight average particle diameter of about several hundred nm or less. In the present invention, the weight average particle diameter of the "nanoparticle" is not particularly limited, and may be, for example, 1nm or more, 10nm or more, 50nm or more, 100nm or more, 150nm or more, 200nm or more, or 250nm or more, for example, 300nm or less, 250nm or less, 200nm or less, 100nm or less, 50nm or less, 40nm or less, 30nm or less, 20nm or less, or 10nm or less, for example, 1～300nm、1～250nm、1～200nm、1～100nm、1～50nm、10～300nm、10～250nm、10～200nm、10～100nm、50～300nm、50～250nm、50～200nm、50～100nm、100～300nm、100～250nm、1～10nm、10～50nm、50～100nm、100～200nm or 200 to 300nm.

In the present invention, the method for measuring the weight average particle diameter is not particularly limited, and is, for example, as follows. For example, the average particle diameters of the antiglare particles and the nanoparticles in the antiglare layer can be measured by TEM (Transmission Electron Microscope; transmission electron microscope) analysis of a cross section of the antiglare layer, and can be estimated as a weight average particle diameter. Specifically, the weight average particle diameter can be estimated from the value obtained by averaging the particle diameters (the value obtained by dividing the sum of the major axis and the minor axis by 2) of all particles observed in the 0.5 μm×0.5 μm region in the TEM image of the cross section. In the measurement of the weight average particle diameter of the antiglare particles or the nanoparticles in the antiglare particles or the material (solution) in which the nanoparticles are dispersed, the measurement can be performed by, for example, light scattering or diffraction.

As described above, in the antiglare film of the present invention, for example, the ratio of the weight average particle diameter of the antiglare particles to the weight average particle diameter of the nanoparticles may satisfy the above formula (3). That is, the weight average particle diameter A [ nm ] of the antiglare particles divided by the weight average particle diameter B [ nm ] of the nanoparticles may have a value (A/B) of 20 to 200. By properly adjusting the ratio of the antiglare particles to the nanoparticles, it becomes easier to achieve both antiglare properties and adhesion to the other layer. The (a/B) is not particularly limited, and may be, for example, 20 or more, 25 or more, 30 or more, 35 or more, or 40 or more, for example, 200 or less, 190 or less, 180 or less, 170 or 160 or less, for example, 20 to 200, 25 to 190, 30 to 190, or 30 to 180.

As described above, for example, the antiglare film of the present invention may satisfy the above formula (4) in terms of the mass ratio of the antiglare particles to the nanoparticles. That is, the number (b/a) obtained by dividing the mass fraction b of the nanoparticles in the antiglare layer by the mass fraction a of the antiglare particles in the antiglare layer may be 2 to 60. By properly adjusting the mass ratio of the antiglare particles to the nanoparticles in this way, for example, effects such as an improvement in the hardness of the antiglare film itself, suppression of cracking (crazing) during bending, suppression of whitening (increase in haze due to the antiglare particles) of the antiglare film can be obtained. The (b/a) is not particularly limited, and may be, for example, 2 or more, 3 or more, 4 or more, 5 or more, or 6 or more, and may be, for example, 60 or less, 58 or less, 56 or less, 54 or 52 or less, and may be, for example, 2 to 60, 3 to 58, 4 to 58, or 4 to 56.

In the antiglare layer, the content of the antiglare particles is not particularly limited, and may be, for example, 1 mass% or more, 3 mass% or more, 5 mass% or more, 7 mass% or more, or 9 mass% or more, for example, 25 mass% or less, 23 mass% or less, 21 mass% or less, 19 mass% or less, or 17 mass% or less, for example, 1 to 25 mass%, 1 to 23 mass%, 3 to 21 mass%, or 5 to 21 mass% based on the mass (weight) of the entire antiglare layer. The content of the antiglare particles is preferably not too small from the viewpoint of film blushing and glare, and the content of the antiglare particles is preferably not too small from the viewpoint of antiglare properties.

In the antiglare layer, the content of the nanoparticles is not particularly limited, and may be, for example, 10 mass% or more, 15 mass% or more, 20 mass% or more, 25 mass% or more, or 30 mass% or more, for example, 80 mass% or less, 75 mass% or less, 70 mass% or less, 65 mass% or less, 60 mass% or less, or 55 mass% or less, for example, 10 to 80 mass%, 15 to 75 mass%, 20 to 75 mass%, or 20 to 70 mass%, based on the mass (weight) of the entire antiglare layer. The content of the nanoparticles is preferably not too small from the viewpoint of film processability and bendability, and the content of the nanoparticles is preferably not too small from the viewpoints of adhesion of the AR layer and film hardness.

As described above, the antiglare film of the present invention can satisfy the above expression (5), for example, in a ratio of the average height Ra nm of the irregularities to the weight average particle diameter a nm of the antiglare particles. That is, the weight average particle diameter A nm of the antiglare particles divided by the average height Ra nm of the irregularities may be 10 to 30. By making (a/Ra) excessively large, for example, the antiglare particles are not excessively exposed from the surface of the antiglare layer, and thus the binding force of the antiglare layer forming material (for example, when the antiglare layer is an antiglare hard coat layer, hard coat resin or the like) with the antiglare particles can be maintained. Further, when (a/Ra) is not too small (Ra is not too large), for example, the scratch resistance of the antiglare layer can be improved and screen glare can be suppressed. Further, by setting the (a/Ra) within an appropriate range, for example, better antiglare property can be obtained. The (a/Ra) is not particularly limited, and may be, for example, 10 or more, 12 or more, 14 or more, 16 or more, or 18 or more, for example, 30 or less, 28 or less, 26 or less, 24 or less, or 22 or less, for example, 10 to 30, 12 to 28, 14 to 28, or 14 to 26.

As described above, the antiglare film of the present invention can satisfy the above expression (6), for example, in a ratio of the surface roughness Sa [ nm ] of the irregularities to the weight average particle diameter B [ nm ] of the nano silica particles. That is, the weight average particle diameter B [ nm ] of the nano silica particles divided by the surface roughness Sa [ nm ] of the irregularities has a value (B/Sa) of 2.5 to 50. When the (B/Sa) is within an appropriate range, for example, the adhesion between the antiglare layer and the other layer is further improved. In addition, since the (B/Sa) is not excessively large, for example, the nano silica particles are not excessively exposed from the antiglare layer surface, and thus the binding force of the antiglare layer forming material (for example, a hard coat resin or the like when the antiglare layer is an antiglare hard coat layer) with the nano particles can be maintained. In addition, since the (B/Sa) is not too small, for example, the nano silica particles are moderately exposed from the antiglare layer surface, the slidability of the antiglare layer surface is improved, and blocking at the time of conveying the antiglare film can be suppressed or prevented. The (B/Sa) is not particularly limited, and may be, for example, 2.5 or more, 3 or more, 3.5 or more, 4 or more, or 4.5 or more, for example, 50 or less, 48 or less, 46 or less, 44 or 42 or less, and may be, for example, 2.5 to 50, 3 to 48, 3.5 to 48, or 3.5 to 46.

In the antiglare film of the present invention, for example, the entire antiglare film may have a light transmittance at a wavelength of 550nm of 90% or more. The light transmittance of the entire antiglare film at a wavelength of 550nm may be, for example, 90% or more, 92% or more, 94% or more, 95% or more, 96% or more, 97% or more, 98% or more, or 99% or more, and may be, for example, 100% or less, 99% or less, 98% or less, 97% or less, 96% or less, 95% or less, 94% or less, 93% or less, 92% or less, or 90% or less, and may be, for example, 90～100％、90～99％、90～98％、90～97％、90～96％、90～95％、90～94％、90～93％、90～92％、92～100％、92～99％、92～98％、92～97％、92～96％、92～95％、92～94％、92～93％、94～100％、94～99％、94～98％、94～97％、94～96％、94～95％、95～100％、95～99％、95～98％、95～97％、95～96％、96～100％、96～99％、96～98％、96～97％、97～100％、97～99％、97～98％、98～100％、98～99％ or 99 to 100%. The antiglare film has a high light transmittance as a whole, and thus has an advantage of easy appearance inspection, for example, because the brightness and transparency are not impaired when the film is formed into a polarizing plate.

In the present invention, the method for measuring the light transmittance is not particularly limited, and the measurement can be performed by the following measurement method, for example.

[ Method for measuring light transmittance ]

Device: integrating sphere type spectral transmittance tester (trade name: DOT-3C, manufactured by color technology research institute, village)

Measurement mode: full light transmittance & color calculation

Light source: d65 light source

Viewing angle: 2 degree field of view

By the above setting, the transmittance at 550nm was measured under the measurement conditions of an air temperature of 23℃and a humidity of 50%.

[2 ] Method for producing antiglare film ]

The method for producing the antiglare film of the present invention is not particularly limited, and for example, the method can be performed in the same manner as a general method for producing an antiglare film. Hereinafter, a method for producing an antiglare film according to the present invention will be described by way of example. In the following, the case where the antiglare layer is an antiglare hard coat layer (that is, the case where the antiglare film of the present invention is an antiglare hard coat film) will be mainly described.

First, a base material 11 shown in fig. 1 or 2 is prepared, and an antiglare layer 12 is formed on one surface thereof.

The substrate 11 is not particularly limited, and may be a light-transmitting substrate, for example, and specifically, a transparent plastic film substrate or the like may be mentioned. The transparent plastic film substrate is not particularly limited, but is preferably excellent in light transmittance of visible light (preferably, light transmittance of 90% or more) and excellent in transparency (preferably, haze value of 1% or less), and examples thereof include the transparent plastic film substrate described in japanese patent application laid-open No. 2008-90263. As the transparent plastic film base material, one having less optical birefringence is preferably used. The antiglare film of the present invention can be used as a protective film for a polarizing plate, and in this case, a film formed of triacetyl cellulose (TAC), polycarbonate, an acrylic polymer, a polyolefin having a cyclic or norbornene structure, or the like is preferable as the transparent plastic film base material. In the present invention, the transparent plastic film base material may be a polarizing plate itself. According to such a configuration, since the structure of the polarizing plate can be simplified without the need for the protective layer made of TAC or the like, the number of manufacturing steps of the polarizing plate or the image display device can be reduced, and the production efficiency can be improved. In addition, if the structure is such, the polarizing plate can be made thinner. In addition, in the case where the transparent plastic film base material is a polarizing plate, for example, the non-transparent layer can function as a protective layer. In addition, in the case of such a structure, the antiglare film of the present invention can also function as a cover sheet when attached to the surface of a liquid crystal cell, for example.

In the present invention, the thickness of the substrate is not particularly limited, for example, as described above. The refractive index of the substrate is not particularly limited. The refractive index is, for example, in the range of 1.30 to 1.80 or 1.40 to 1.70.

In the present invention, unless otherwise specified, "refractive index" means a refractive index having a wavelength of 550 nm. In the present invention, the method for measuring the refractive index is not particularly limited, and in the case of the refractive index of a fine substance such as particles, for example, measurement can be performed by the beck method. The Beckmethod refers to the following assay: the measurement sample was dispersed in a standard refractive fluid on a glass slide, and when the glass slide was observed with a microscope, the refractive index of the standard refractive fluid at the time of disappearance or blurring of the outline of the sample was used as the refractive index of the sample. The method for measuring the refractive index of an object (for example, an antiglare film, an antiglare layer, or a resin constituting the antiglare layer) whose refractive index cannot be measured by the beck method is not particularly limited, and for example, a general refractometer (an instrument for measuring refractive index) may be used for measurement. The refractometer is not particularly limited, and examples thereof include an abbe refractometer. Examples of the Abbe refractometer include a multi-wavelength Abbe refractometer DR-M2/1550 (trade name) manufactured by ATAGO, inc.

The method of forming the antiglare layer 12 on the substrate 11 is not particularly limited, and is, for example, as follows. Hereinafter, the step of forming the antiglare layer 12 may be referred to as "antiglare layer forming step". The antiglare layer forming step includes, for example: a coating step of coating a coating liquid for forming an antiglare layer (hereinafter, sometimes simply referred to as "coating liquid" or "antiglare layer forming material") on the base material 110, and a coating film forming step of drying the coated coating liquid to form a coating film. In addition, for example, the antiglare layer forming step may further include a curing step of curing the coating film. The curing may be performed, for example, after the drying, but is not limited thereto. The curing may be performed by, for example, heating, light irradiation, or the like. The light is not particularly limited, and may be ultraviolet light, for example. The light source for the light irradiation is not particularly limited, and may be, for example, a high-pressure mercury lamp.

The coating liquid (antiglare layer forming material) may be, for example, a coating liquid containing a resin material and a diluting solvent (hereinafter, may be simply referred to as "solvent") and antiglare particles 12b and nanoparticles 12 c. The coating liquid may contain other components than these, other components than these may not be contained. The other components are not particularly limited, and examples thereof include a thixotropic agent and the like.

The resin material contained in the coating liquid may be, for example, the resin itself that forms the antiglare layer forming material 12a in the antiglare layer 12, or may be a resin material that forms the resin by polymerization, curing, or the like. The resin is not particularly limited, and may be, for example, a thermosetting resin, an ionizing radiation curing resin, or the like. The resin may contain, for example, an acrylic resin (also referred to as an acrylic resin), and may contain, for example, a urethane acrylic resin. The resin may be, for example, a copolymer of a curable urethane acrylate resin and a polyfunctional acrylate.

The resin material may contain, for example, an oligomer and a monomer having a functional group. For example, the resin forming the antiglare layer forming material 12a may be a copolymer of an oligomer having the functional group and the monomer. The oligomer having a functional group is not particularly limited, and examples thereof include a curable urethane acrylate resin. Examples of the curable urethane acrylate resin include trade names "UV-1700TL" manufactured by Mitsubishi chemical corporation, and trade name "UT-7314" manufactured by Mitsubishi chemical corporation. The monomer is not particularly limited, and examples thereof include polyfunctional acrylates and the like. Examples of the polyfunctional acrylate include a product name "M-920" manufactured by Toyama Synthesis Co., ltd.

The solvent is not particularly limited, and various solvents may be used, and one may be used alone, or two or more may be used in combination. For example, the optimum solvent type and solvent ratio may be appropriately selected according to the composition of the resin, the types and contents of the nano silica particles and the thixotropic agent, and the like. The solvent is not particularly limited, and examples thereof include: alcohols such as methanol, ethanol, isopropyl alcohol (IPA), butanol, t-butanol (TBA), and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclopentanone; esters such as methyl acetate, ethyl acetate, and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, octane, etc.; aromatic hydrocarbons such as benzene, toluene and xylene. In addition, for example, the solvent may contain a hydrocarbon solvent and a ketone solvent. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be, for example, at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene. The ketone solvent may be, for example, at least one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. For dissolving the thixotropic imparting agent (e.g., thickener), the solvent preferably contains, for example, the hydrocarbon solvent (e.g., toluene). The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent at 90: 10-10: 90 mass ratio of the solvent. The mass ratio of the hydrocarbon solvent to the ketone solvent may be, for example, 80: 20-20: 80. 70: 30-30: 70 or 40: 60-60: 40, etc. In this case, for example, the hydrocarbon solvent may be toluene and the ketone solvent may be methyl ethyl ketone. In addition, the solvent contains, for example, at least one selected from the group consisting of toluene, and further contains ethyl acetate, butyl acetate, IPA, methyl isobutyl ketone, methyl ethyl ketone, methanol, ethanol, and TBA.

For example, when an intermediate layer (penetration layer) is formed using an acrylate film, a good solvent for the acrylate film (acrylate resin) can be preferably used as the base material 11. As the solvent, for example, as described above, a solvent containing a hydrocarbon solvent and a ketone solvent may be used. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be, for example, at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene. The ketone solvent may be, for example, any one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent at 90: 10-10: 90 mass ratio of the solvent. The mass ratio of the hydrocarbon solvent to the ketone solvent may be, for example, 80: 20-20: 80. 70: 30-30: 70 or 40: 60-60: 40, etc. In this case, for example, the hydrocarbon solvent may be toluene and the ketone solvent may be methyl ethyl ketone.

In the case of using triacetyl cellulose (TAC), for example, the solvent is not particularly limited, and examples thereof include ethyl acetate, methyl ethyl ketone, MIBK (methyl isobutyl ketone), cyclopentanone, and the like, and one or more of them may be used. In this case, the solvent may be a mixed solvent of MIBK and cyclopentanone, for example. The mixing ratio of MIBK and cyclopentanone is not particularly limited, and for example, may be 90 in terms of mass ratio: 10-10: 90. 80: 20-20: 80. 70: 30-30: 70.

In addition, by appropriately selecting the solvent, thixotropic properties to the antiglare hard coat layer forming material (coating liquid) can be exhibited well when the thixotropic agent is contained. For example, in the case of using organoclay, toluene and xylene may be preferably used alone or in combination, for example, in the case of using oxidized polyolefin, methyl ethyl ketone, ethyl acetate, propylene glycol monomethyl ether, for example, in the case of using modified urea, butyl acetate and methyl isobutyl ketone may be preferably used alone or in combination.

Various leveling agents may be added to the antiglare layer forming material. As the leveling agent, for example, a fluorine-based or silicone-based leveling agent can be used to prevent uneven coating (leveling of the coating surface). In the present invention, the leveling agent may be appropriately selected depending on the case where antifouling property is required on the surface of the antiglare layer, the case where the antireflection layer (low refractive index layer) of the other layer or the layer containing the interlayer filler is formed on the antiglare layer, or the like.

The amount of the leveling agent to be blended is, for example, 5 parts by weight or less, preferably 0.01 to 5 parts by weight, based on 100 parts by weight of the resin.

To the antiglare layer forming material, pigments, fillers, dispersants, plasticizers, ultraviolet absorbers, surfactants, antifouling agents, antioxidants, and the like may be added as necessary within a range that does not impair the performance. These additives may be used singly or in combination of two or more.

As the antiglare layer forming material, a conventionally known photopolymerization initiator, for example, as described in japanese unexamined patent publication No. 2008-88309, can be used.

As a method of forming a coating film by applying the antiglare layer forming material (coating liquid) to the substrate 11, for example, a coating method such as a spray coating method, a die coating method, a spray coating method, a gravure coating method, a roll coating method, or a bar coating method can be used.

Next, the coating film is dried and cured as described above, to form an antiglare layer. The drying may be, for example, natural drying, air drying by blowing, heating drying, or a combination thereof.

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

The curing means of the coating film is not particularly limited, and ultraviolet curing is preferable. The cumulative exposure amount of 365nm ultraviolet light is preferably 50 to 500mJ/cm ². If the irradiation amount is 50mJ/cm ² or more, the curing is easily and sufficiently performed, and the hardness of the antiglare layer to be formed is easily increased. In addition, if the irradiation amount is 500mJ/cm ² or less, coloring of the formed antiglare layer can be prevented.

By performing the operation as described above, the antiglare film 10 shown in fig. 1 can be produced. Further, as shown in fig. 2, other layers 13 may be formed on the antiglare layer 12. The other layer 13 and the method of forming the same are not particularly limited, and for example, as described above, the antireflection layer (AR layer) may be formed by a dry method such as sputtering or vapor deposition as the other layer 13.

The antiglare film of the present invention can be produced by performing the operation as described above. However, as described above, this production method is illustrative, and the production method of the antiglare film of the present invention is not limited thereto.

The method for producing the antiglare film of the present invention may be, for example, a continuous production method. Specifically, for example, the method for producing an antiglare film of the present invention may be a method for producing: the antiglare layer forming step and other steps as needed (for example, a step of continuously forming the other layers may be performed) are performed while the base material is being conveyed in a long form. More specifically, for example, the elongated base material is in the form of a roll, and the method for producing an antiglare film of the present invention can be carried out while the base material is pulled out from the roll.

[3 ] Antiglare film, optical member and image display apparatus ]

The antiglare film of the present invention is not particularly limited, and may be, for example, an antiglare hard coat film as described above.

The optical member of the present invention is not particularly limited, and may be, for example, a polarizing plate. The polarizing plate is not particularly limited, and may contain, for example, the antiglare film and the polarizing plate of the present invention, and may also contain other components. The respective constituent elements of the polarizing plate may be bonded by, for example, an adhesive or an adhesive.

The image display device of the present invention is not particularly limited, and may be any image display device, and examples thereof include a liquid crystal display device, an organic EL display device, an inorganic EL display device, and a plasma display device.

The configuration of the image display device of the present invention is not particularly limited, and for example, the same configuration as that of a general image display device may be used. For example, in the case of an LCD, the LCD can be manufactured by appropriately assembling optical members such as a liquid crystal cell and a polarizing plate, and incorporating a driving circuit or the like into each component such as an illumination system (backlight or the like) as necessary.

The application of the image display device of the present invention is not particularly limited, and the device can be used for any application. Examples of the application include: OA equipment such as personal computer monitors, notebook computers, tablet computers, smartphones, copiers, and the like; portable devices such as mobile phones, clocks, digital cameras, portable information terminals (PDAs), portable game machines, and the like; household electrical equipment such as video cameras, televisions, microwave ovens, and the like; a rear monitor, a monitor for a car navigation system, a car audio, and other car-mounted devices; display equipment such as information monitors for commercial stores; a security device such as a monitor for monitoring; nursing and medical equipment such as nursing monitor and medical monitor; smart glasses, VR machines, etc. The image display device of the present invention may be, for example, an image display device having a camera function. In this case, for example, as described above, the transparent layer in the hard coat film of the present invention may be a transparent layer for a camera hole of an image display device. According to the present invention, as described above, it is possible to provide a hard coat film that does not impair the transparency of the transparent layer, and thus, for example, it is possible to provide an image display device that does not impair the image quality of a camera image.

Examples

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

In the following examples and comparative examples, parts by weight of the substances are parts by weight unless otherwise specified. Unless otherwise specified, the "average particle diameter" is a weight average particle diameter.

Example 1

The antiglare film of example 1 was produced by the following procedure. First, as a resin contained in the antiglare layer forming material, a mixture of 83 parts by weight of an acrylate resin (trade name "NC035HS", manufactured by the chemical industry of waste, and 50% by weight of solid content) to which nano silica (nano particles) was added and 17 parts by weight of a urethane acrylate resin (trade name "BEAMSET580", manufactured by the chemical industry of waste, and 70% by weight of solid content) was prepared. Next, for every 100 parts by weight of the solid content of the above resin, 4 parts by weight of crosslinked polymethyl methacrylate particles (trade name "Techpolymer SSX-103", weight average particle diameter: 3 μm, refractive index: 1.495) as antiglare particles, 2 parts by weight of synthetic montmorillonite (trade name "Smecton SAN", manufactured by CO-OP CHEMICAL Co., ltd.), 3 parts by weight of photopolymerization initiator (trade name "OMNIRAD" 907, manufactured by BASF Co., ltd.) as an organoclay as a thixotropic agent, and 0.15 part by weight of leveling agent (trade name "LE303", manufactured by Co., ltd.) were mixed. The organoclay was diluted with toluene to a solid content of 6% and used. The mixture was diluted with butyl acetate to have a solid content concentration of 42 wt%, and further mixed using an ultrasonic disperser to obtain a uniform antiglare layer forming material (coating liquid).

Further, an antiglare layer forming step of forming an antiglare layer on the light-transmitting substrate is performed using the antiglare layer forming material (coating liquid). That is, first, the antiglare layer-forming material (coating liquid) was coated on a triacetyl cellulose base material (thickness 80 μm, trade name KC8UA, manufactured by konikama dada corporation). Then, the resultant was heated at 80℃for 60 seconds to dry the resultant film, and an ultraviolet ray having a wavelength of 365nm was irradiated with a high-pressure mercury lamp to bring the cumulative light amount to 210mJ/cm ², whereby the resin in the antiglare layer-forming material (coating liquid) was cured to form an antiglare layer having a thickness of 8. Mu.m on a triacetyl cellulose substrate. The antiglare film of this example was produced by performing the operation as described above.

Example 2

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the blending amount of the "Smecton SAN" was changed from 2 parts by weight to 2.5 parts by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 2) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 3

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the blending amount of the "Smecton SAN" was changed from 2 parts by weight to 3 parts by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 3) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 4

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of the "technopolymer SSX-103" was changed from 4 parts by weight to 3 parts by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 4) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 5

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 67 parts by weight, the amount of "BEAMSET580" was changed to 33 parts by weight, the amount of "technopolymer SSX-103" was changed to 2 parts by weight, and the liquid solid content concentration was changed from 42% by weight to 45% by weight, respectively. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 4) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 6

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 91 parts by weight and the amount of "BEAMSET580" was changed to 9 parts by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 6) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 7

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 100 parts by weight and the amount of "BEAMSET580" was changed to 0 parts by weight (i.e., no "BEAMSET 580") respectively. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 7) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 8

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the "NC035HS" was changed to 50 parts by weight, the "BEAMSET580" was changed to 50 parts by weight, and the "Smecton SAN" was changed to 3 parts by weight, respectively. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 8) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 9

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 83 parts by weight, the amount of "BEAMSET580" was changed to 17 parts by weight, and the antiglare particles were changed to crosslinked polymethyl methacrylate particles (trade name "technopolymer SSX-104", manufactured by water-logging end product industry Co., ltd., weight average particle diameter: 4 μm, refractive index: 1.495) and the same amount (4 parts by weight) was used. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 9) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 10

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 83 parts by weight, the amount of "BEAMSET580" was changed to 17 parts by weight, and the antiglare particles were changed to crosslinked polymethyl methacrylate particles (trade name "technopomer SSX-106", manufactured by water-logging end product industry Co., ltd., weight average particle diameter: 6 μm, refractive index: 1.495), respectively, and then the same amount (4 parts by weight) was used and the liquid solid content concentration was changed from 42% by weight to 45% by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 10) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 11

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the resin contained in the antiglare layer forming material was not used in example 1, but a mixed liquid of 50 parts by weight of urethane acrylate resin (trade name "BEAMSET580", manufactured by the product of the chemical industry of waste and Sichuan Co., ltd., solid content of 70%) and 50 parts by weight of a nano silica (nanoparticle) dispersion (trade name "SIRMIBK WT% -S190", manufactured by the product of the company CIK NANOTECH, solid content of 30%) and the liquid solid content concentration was changed from 42% by weight to 37% by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 11) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 12

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the antiglare particles were changed to crosslinked polymethyl methacrylate particles (trade name "technopomer XX-41AA", manufactured by water-logging end product Co., ltd., weight average particle diameter: 8 μm, refractive index: 1.505) and the same amount (4 parts by weight) was used. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 12) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 13

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the blending amount of the "technopolymer" was changed to 1 part by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 13) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 14

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the blending amount of the "technopolymer" was changed to 2 parts by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 14) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 15

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of the "technopolymer" was changed to 3 parts by weight and the concentration of the liquid solid content was changed from 42% by weight to 45% by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 15) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 16

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the blending amount of the "technopolymer" was changed to 30 parts by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 16) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 17

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of the "technopolymer" was changed to 25 parts by weight and the concentration of the liquid solid content was changed from 42% by weight to 45% by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 17) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 18

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 7, except that the blending amount of the "technopolymer" was changed to 0.5 part by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 18) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 19

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 7, except that the blending amount of the "technopolymer" was changed to 1 part by weight. Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 19) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Example 20

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 11, except that the resin contained in the antiglare layer forming material was not a resin of example 11, but a mixed liquid of 90 parts by weight of urethane acrylate resin (trade name "BEAMSET580", manufactured by the product of the chemical industry of waste and Sichuan Co., ltd., solid content: 70%) and 10 parts by weight of a nano silica (nanoparticle) dispersion (trade name "SIRMIBK WT% -S190", manufactured by the product of the chemical industry of CIK NANOTECH Co., ltd., solid content: 30%). Further, an antiglare film of this example was produced by performing the antiglare layer forming step in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this example (example 20) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1.

Comparative example 1

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 67 parts by weight, the amount of "BEAMSET580" was changed to 33 parts by weight, the amount of "technopomer" was changed to 2 parts by weight, the amount of "Smecton SAN" was changed to 1.5 parts by weight, and the liquid solid content concentration was changed from 42% by weight to 45% by weight. Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 1) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 2

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 67 parts by weight, the amount of "BEAMSET580" was changed to 33 parts by weight, the amount of "technopomer" was changed to 7 parts by weight, the amount of "Smecton SAN" was changed to 1.5 parts by weight, and the liquid solid content concentration was changed from 42% by weight to 37% by weight. Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 2) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 3

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 67 parts by weight, the amount of "BEAMSET580" was changed to 33 parts by weight, and the amount of "technopolymer" was changed to 0 part by weight (i.e., no "technopolymer" was added). Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 3) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 4

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 100 parts by weight, the amount of "BEAMSET580" was changed to 0 parts by weight, the amount of "technopomer" was changed to 1 part by weight, and the amount of "Smecton SAN" was changed to 0 parts by weight (i.e., no "Smecton SAN" was added). Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 4) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 5

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 33 parts by weight and the amount of "BEAMSET580" was changed to 67 parts by weight. Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 5) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 6

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that 100 parts by weight of an acrylate resin (trade name "OPSTARZ7540", manufactured by the product of the schwann chemical industry, 56% by weight of solid content) to which nano silica (nanoparticles) was added was used instead of the "NC035HS" as the resin contained in the antiglare layer forming material. Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 6) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 7

An antiglare layer-forming material (coating liquid) was prepared in the same manner as in example 1 except that the resin contained in the antiglare layer-forming material was not a resin of example 1, but a mixture of 50 parts by weight of urethane acrylate resin (trade name "BEAMSET580", manufactured by the product of the chemical industry of waste and Sichuan Co., ltd., solid content: 70%) and 50 parts by weight of a nano silica (nanoparticle) dispersion (trade name "SIRMIBK WT% -S190", manufactured by the product of the chemical industry of CIK NANOTECH, solid content: 30%) was used, and the concentration of the liquid solid content was changed from 42% to 37% by weight, and the antiglare particles were changed to crosslinked polymethyl methacrylate particles (trade name "technopolymerssx-101", manufactured by the product of the water-logging industry Co., ltd., average weight particle diameter: 1.5 μm, refractive index: 1.495) and then the same amount (4 parts by weight) was used. Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 7) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

Comparative example 8

An antiglare layer forming material (coating liquid) was prepared in the same manner as in example 1, except that the amount of "NC035HS" was changed to 67 parts by weight and the amount of "BEAMSET580" was changed to 33 parts by weight. Further, an antiglare layer forming step was performed in the same manner as in example 1, except that the antiglare layer forming material (coating liquid) prepared in this comparative example (comparative example 8) was used instead of the antiglare layer forming material (coating liquid) prepared in example 1, to produce an antiglare film of this comparative example.

The antiglare films of examples and comparative examples were measured by the following method for the surface roughness Sa of the irregularities on the antiglare layer surface, the average height Ra of the irregularities, and the average inter-irregularity distance Sm. The values are shown in tables 1 and 2 below.

[ Method for measuring surface roughness Sa of irregularities on the antiglare layer surface ]

The surface height Sa of the irregularities on the antiglare layer surface was measured using an AFM5500M (trade name of hitachi high technology, inc.) as an atomic force microscope (AFM, atomic Force Microscope). The measurement mode was high resolution, the resolution was 256×256 points, and the scanning frequency was set to 0.65Hz, respectively, to measure.

[ Method for measuring the average height Ra of the irregularities on the antiglare layer surface and the average inter-irregularity distance Sm ]

On the surface of the antiglare film on which the antiglare layer was not formed, a glass plate (thickness: 1.3 mm) made by Song glass Co., ltd was bonded with an adhesive, and the surface shape of the antiglare layer was measured under the condition of a cutoff value of 0.8mm using a high-precision fine shape measuring instrument (trade name; SURFCODER ET4000,4000, manufactured by Kagaku Kogyo Co., ltd.), to calculate an arithmetic average surface roughness Ra, an average inter-concave-convex distance Sm, and an average tilt angle θa. The high-precision fine shape measuring device automatically calculates the arithmetic average surface roughness Ra and the average inclination angle θa. The arithmetic average surface roughness Ra and the average tilt angle θa are based on JIS B0601 (1994 edition). The average inter-concave-convex distance Sm is an average inter-concave-convex distance of a surface measured according to JIS B0601 (1994 edition). In addition, "arithmetic average surface roughness Ra" and "average height of irregularities Ra" are synonymous.

The antiglare films of examples and comparative examples were evaluated for adhesion (AG-AR adhesion) between the antiglare layer (AG) and the antireflection layer (AR) by the following methods. The evaluation results are shown in tables 1 and 2 below.

[ Evaluation method of AG-AR adhesion ]

UV (ultraviolet) was irradiated under the following conditions. Then, AG-AR adhesion (peeling) after UV irradiation was evaluated. In the following text, "RH" represents relative humidity, and "BPT" represents temperature measured by a blackboard thermometer.

(UV irradiation conditions)

Light source: metal halides

Environment: 50-60 ℃/45% RH

Irradiation intensity: 1500W/m ²

BPT：85℃

Time: 32.5 hours

UV irradiator: trade name "SUV-W161" (manufactured by Kawasaki electric Co., ltd.)

AG-AR adhesion (peeling) after UV irradiation was evaluated as follows. First, as described above, for the antiglare film after UV irradiation, a jig having a contact area with the antiglare film of 10mm×10mm was pressed on the antireflection layer side. At this time, a cleaning wiper (trade name "ANTICON GOLD", manufactured by Contec corporation) is sandwiched between the jig and the antiglare film, and the jig is pressed. Next, a load of 2.5kg was applied to the jig, and the condition of the antiglare film was visually confirmed after a distance of 10cm per pass was repeated 10 times in this state. If a visually identifiable flaw (AR peeling) was generated, it was evaluated as poor adhesion (x), and if a visually identifiable flaw (AR peeling) was not generated, it was evaluated as no peeling and good adhesion (o).

The antiglare films of the examples and comparative examples were evaluated for antiglare properties by the following methods. The evaluation results are shown in tables 1 and 2 below.

[ Method of evaluating antiglare property ]

In a state where an antiglare film is attached to a glass having a black tape attached to the back surface thereof with the antiglare layer side as the upper surface, the antiglare film was projected in a state where a fluorescent lamp having a diameter of 32mm provided on 2m was turned on. The fluorescent lamp was evaluated as having good antiglare properties (o) when the outline of the fluorescent lamp was in an unrecognizable state due to blurring, and as having poor antiglare properties (x) when the outline of the fluorescent lamp was in a recognizable state.

Further, the antiglare films of examples and comparative examples were evaluated for pencil hardness, cracking resistance, whitening and scratch resistance by the following methods. The evaluation results are shown in tables 1 and 2 below.

[ Method for testing Pencil hardness and evaluation method ]

The antiglare films of each of the examples and comparative examples were subjected to pencil hardness test in accordance with JIS K5600-5-4. Specifically, a pencil of a predetermined hardness was provided on the antiglare layer side surface of the antiglare film, a weight of 500g was placed, and the surface of the antiglare layer was tested for scratches by moving 3mm at a speed of about 0.5mm per second. The hardness of pencil whose breakage or cutting of the antiglare layer was 2 times or more in 5 tests was one level or less was recorded, and the hardness was regarded as an evaluation result.

[ Method of evaluating cracking resistance ]

For a cylindrical jig having a diameter of 3mm, the surface of the antiglare film on the antiglare layer side was wound so as to face the jig for 10 seconds without forming a gap. Then, whether or not the surface of the antiglare layer was scratched was confirmed by visual observation or an optical microscope. An antiglare film in which occurrence of a flaw was visually confirmed was evaluated as "x", an antiglare film in which no flaw was visually confirmed but occurrence of a flaw was confirmed by an optical microscope at 5 times magnification was evaluated as "Δ", and an antiglare film in which occurrence of a flaw was not confirmed by an optical microscope at 5 times magnification was evaluated as "o".

[ Whitening evaluation method ]

The antiglare films of examples and comparative examples were set on a sample stage so as to emit light from the antiglare layer side, and haze measurement was performed. The haze measurement method was based on JIS K7136 (2000 edition). As a result, the antiglare film having a haze value of more than 50% was judged to be whitened as x, and the antiglare film having a haze value of 50% or less was judged to be o.

[ Method of scratch resistance test and evaluation method ]

A weight for applying a load was placed on a cylindrical jig having a diameter of 25mm, and steel wool #0000 (TRUSCO manufactured by zhongshan corporation) was uniformly mounted on a circular smooth bottom surface. Next, as a sample, antiglare films of each example and comparative example were provided on a glass plate. After the steel wool loaded with the weight reciprocally rubbed the antiglare layer side surface of the test piece 10 times at a speed of 100 mm/sec, the scratch condition of the antiglare layer side surface was confirmed. Tests were performed at loads of 400g, 600g, 800g and 1000g (weights of the loads), and the maximum load at which no visually identifiable flaw was generated was recorded.

The ratio A/B of the weight average particle diameter A nm of the antiglare particles to the weight average particle diameter B nm of the nanoparticles, the ratio B/a of the mass fraction a of the antiglare particles to the mass fraction B of the nanoparticles in the antiglare layer, the ratio A/Ra of the average height Ra nm of the irregularities in the antiglare layer to the weight average particle diameter A nm of the antiglare particles, and the ratio B/Sa of the surface roughness Sanm of the irregularities in the antiglare layer to the weight average particle diameter B nm of the nanosilica particles are also shown in tables 1 and 2 below.

As shown in tables 1 and 2, examples 1 to 20, in which both the surface roughness Sa of the surface roughness of the antiglare layer and the average height Ra of the surface roughness of the antiglare layer were within the scope of the present invention, were able to achieve both antiglare properties of the antiglare film and adhesion between the antiglare layer and the antireflection layer. In contrast, the antiglare film of comparative example 1, in which both Sa and Ra were outside the range of the present invention, had poor antiglare properties and adhesion between the antiglare layer and the antireflection layer. Although comparative examples 2, 4 to 6 and 8, in which Ra was within the scope of the present invention but Sa was outside the scope of the present invention, were excellent in antiglare properties, the antiglare layer and the antireflection layer were poor in adhesion. Sa is within the scope of the present invention, but Ra is outside the scope of the present invention, and the antiglare layer and the antireflection layer of comparative examples 3 and 7 have good adhesion but poor antiglare properties.

The present invention can be described, for example, as follows. The following supplementary notes are illustrative, however, and the invention is not limited to these modes.

(Additionally, 1)

An antiglare film comprising an antiglare layer, wherein the antiglare layer comprises antiglare particles and nanoparticles, and wherein irregularities are formed on one surface of the antiglare layer, and wherein the irregularities on the surface of the antiglare layer satisfy the following expressions (1) and (2):

2≤Sa≤8 (1)

0.1×10³≤Ra (2)

(Additionally remembered 2)

The antiglare film according to appendix 1, wherein the antiglare layer is laminated on a substrate, and the irregularities are formed on a surface of the antiglare layer on a side opposite to the substrate.

(Additionally, the recording 3)

The antiglare film according to appendix 1 or 2, wherein the nanoparticles are inorganic nanoparticles.

(Additionally remembered 4)

The antiglare film according to any one of supplementary notes 1 to 3, wherein the nanoparticle is at least one selected from the group consisting of a nano-oxidized metal particle, a nano-silica particle, a nano-metal particle, and a nano-diamond.

(Additionally noted 5)

The antiglare film according to any one of supplementary notes 1 to 3, wherein the nanoparticle is a nanosilica particle.

(Additionally described 6)

The antiglare film according to any one of supplementary notes 1 to 5, wherein a ratio of a weight average particle diameter of the antiglare particles to a weight average particle diameter of the nanoparticles satisfies the following mathematical formula (3):

20≤(A/B)≤200 (3)

(Additionally noted 7)

The antiglare film according to any one of supplementary notes 1 to 6, wherein in the antiglare layer, a mass ratio of the antiglare particles to the nanoparticles satisfies the following mathematical formula (4):

2≤(b/a)≤60 (4)

(Additionally noted 8)

The antiglare film according to any one of supplementary notes 1 to 7, wherein a ratio of an average height Ra [ nm ] of the irregularities to a weight average particle diameter a [ nm ] of the antiglare particles satisfies the following formula (5):

10≤(A/Ra)≤30 (5)

(Additionally, the mark 9)

The antiglare film according to any one of supplementary notes 1 to 8, wherein a ratio of the surface roughness Sa [ nm ] of the irregularities to the weight average particle diameter B [ nm ] of the nano silica particles satisfies the following mathematical formula (6):

2.5≤(B/Sa)≤50 (6)

(Additionally noted 10)

The antiglare film according to any one of supplementary notes 1 to 9, wherein another layer is further laminated on a surface of the antiglare layer on the side where the irregularities are formed.

(Additionally noted 11)

The antiglare film according to supplementary note 10, wherein the other layer is an antireflection layer.

(Additional recording 12)

An optical member comprising the antiglare film according to any one of supplementary notes 1 to 11.

(Additional recording 13)

The optical member according to supplementary note 12, which is a polarizing plate.

(Additional recording 14)

An image display device comprising the antiglare film according to any one of supplementary notes 1 to 11, or the optical member according to supplementary notes 12 or 13.

Industrial applicability

As described above, according to the present invention, an antiglare film, an optical member, and an image display device that can achieve both antiglare properties and adhesion to other layers can be provided. As described above, the antiglare film of the present invention can be used as an antiglare hard coat film, for example, can be provided with an antireflection layer to impart antireflection property, and can be used for various optical members and image display devices, and therefore has a great industrial application value.

The present application claims priority based on japanese patent application 2023-027063 filed on 24 of month 2023, 02, the entire disclosure of which is incorporated herein.

Description of the reference numerals

10. 10X antiglare film

11 Substrate

12 Antiglare layer

12A antiglare layer forming material

12B antiglare particles

12C nanoparticles

13 Antireflective layer (other layer).

Claims

1. An antiglare film comprising an antiglare layer, wherein the antiglare layer comprises antiglare particles and nanoparticles, and wherein irregularities are formed on one surface of the antiglare layer, and wherein the irregularities on the surface of the antiglare layer satisfy the following expressions (1) and (2):

2≤Sa≤8 (1)

0.1×10³≤Ra (2)

In the above formula (1), sa is the surface roughness in nm of the irregularities, and in the above formula (2), ra is the average height in nm of the irregularities.

2. The antiglare film according to claim 1, wherein the antiglare layer is laminated on a substrate, and the irregularities are formed on a surface of the antiglare layer on a side opposite to the substrate.

3. The antiglare film according to claim 1 or 2, wherein the nanoparticle is an inorganic nanoparticle.

4. The antiglare film according to claim 1 or 2, wherein the nanoparticle is at least one selected from the group consisting of a nano-oxidized metal particle, a nano-silica particle, a nano-metal particle, and a nano-diamond.

5. The antiglare film according to claim 1 or 2, wherein the nanoparticle is a nanosilica particle.

6. The antiglare film according to claim 1 or 2, wherein a ratio of a weight average particle diameter of the antiglare particles to a weight average particle diameter of the nanoparticles satisfies the following mathematical formula (3):

20≤(A/B)≤200 (3)

In the above formula (3), a is the weight average particle diameter in nm of the antiglare particles, and B is the weight average particle diameter in nm of the nanoparticles.

7. The antiglare film according to claim 1 or 2, wherein in the antiglare layer, a mass ratio of the antiglare particles to the nanoparticles satisfies the following mathematical formula (4):

2≤(b/a)≤60 (4)

8. The antiglare film according to claim 1 or 2, wherein a ratio of an average height Ra in nm of the irregularities to a weight average particle diameter a in nm of the antiglare particles satisfies the following mathematical formula (5):

10≤(A/Ra)≤30 (5)

In the above expression (5), ra is the average height Ra in nm of the irregularities as in the above expression (2), and a is the weight average particle diameter a in nm of the antiglare particles as in the above expression (3).

9. The antiglare film according to claim 1 or 2, wherein a ratio of the surface roughness Sa in nm of the irregularities to the weight average particle diameter B in nm of the nano silica particles satisfies the following mathematical formula (6):

2.5≤(B/Sa)≤50 (6)

in the above expression (6), sa is the surface roughness Sa in nm of the irregularities as in the above expression (1), and B is the weight average particle diameter B in nm of the nano silica particles as in the above expression (3).

10. The antiglare film according to claim 1 or 2, wherein another layer is further laminated on a surface of the antiglare layer on the side on which the irregularities are formed.

11. The antiglare film according to claim 10, wherein the other layer is an antireflection layer.

12. An optical member comprising the antiglare film according to claim 1 or 2.

13. The optical member of claim 12 which is a polarizing plate.

14. An image display device comprising the antiglare film according to claim 1 or 2.