阅读说明：本技术 防眩膜 (Anti-dazzle film ) 是由 林正树 菅原庆峰 于 2018-06-25 设计创作，主要内容包括：本发明涉及一种防眩膜,其具备雾度值为50％以上且99％以下范围的值的防眩层,在将所述防眩膜安装于显示器的表面的状态下,显示器的亮度分布的标准偏差为0以上且6以下范围的值,并且,光梳宽度0.5mm的透射图像清晰度为0％以上且60％以下范围的值。(The present invention relates to an antiglare film comprising an antiglare layer having a haze value in the range of 50% to 99%, wherein the standard deviation of the luminance distribution of a display is in the range of 0% to 6% in a state where the antiglare film is attached to the surface of the display, and the transmission image clarity with a comb width of 0.5mm is in the range of 0% to 60%.)

1. An anti-glare film comprising an anti-glare layer having a haze value in the range of 50% to 99%,

in a state where the antiglare film is attached to a surface of a display, a standard deviation of a luminance distribution of the display is a value in a range of 0 or more and 6 or less, and a transmission image clarity of an optical comb width of 0.5mm is a value in a range of 0% or more and 60% or less.

2. The antiglare film of claim 1,

the antiglare layer contains a plurality of resin components and has a co-continuous phase structure formed due to phase separation of the plurality of resin components.

3. The antiglare film of claim 2, wherein the antiglare layer comprises:

acrylic acid copolymer,

Cellulose acetate propionate, and

at least one of an acrylic ultraviolet-curable compound containing nano silica and a urethane acrylate.

4. The antiglare film of claim 1,

the antiglare layer comprises a matrix resin, a plurality of microparticles dispersed in the matrix resin,

the difference in refractive index between the fine particles and the matrix resin is a value in the range of 0 to 0.07.

5. The antiglare film of claim 4,

the ratio G2/G1 of the weight G1 of the matrix resin of the antiglare layer to the total weight G2 of the plurality of fine particles contained in the antiglare layer is a value in the range of 0.07 or more and 0.20 or less.

Technical Field

The present invention relates to an antiglare film for preventing reflection of external light to a display surface.

Background

The antiglare film is a film having an antiglare layer with irregularities formed on the surface thereof by surface roughening, for example, and is attached to the surface of a display to scatter external light and prevent reflection of the external light to the display surface.

Examples of a method for forming the unevenness on the surface of the antiglare layer include: a method of dispersing fine particles (filler) in an antiglare layer as disclosed in patent document 1; a method of utilizing a phase separation structure formed by spinodal decomposition from a liquid phase of a plurality of polymers as disclosed in patent document 2; a method of transfer molding of an uneven shape using a mold as disclosed in patent document 3, and the like.

Disclosure of Invention

Problems to be solved by the invention

When an antiglare film is attached to the surface of a display, although reflection of external light to the display surface can be prevented, on the other hand, light from the display is affected by the antiglare film, and display performance of the display via the antiglare film may be degraded. Therefore, the antiglare film is desired to have a high degree of freedom in designing the transmission image clarity.

Further, if an antiglare film is attached to the surface of a display or the like having high-definition pixels, the light from the display transmitted through the antiglare film is refracted by the surface irregularities of the antiglare layer or the pixels of the display are observed in an enlarged manner due to a lens effect caused by the surface irregularities of the antiglare layer, and this may cause glare on the display or make it difficult to observe an image.

As a method for suppressing glare of the display, for example, it is conceivable to reduce surface irregularities of the antiglare layer, but there is a concern that the antiglare property of the antiglare film may be reduced. Further, there is a problem that it is difficult to quantitatively evaluate the glare of the display, and it may be difficult to develop an antiglare film capable of effectively suppressing the glare of the display according to an objective index.

Accordingly, an object of the present invention is to provide an antiglare film having a good antiglare property, capable of suppressing the glare of a display, and having a high degree of freedom in design of transmission image clarity by quantitatively evaluating the glare of the display and designing.

Means for solving the problems

In order to solve the above problems, one embodiment of the present invention includes an antiglare layer having a haze value in a range of 50% to 99%, a standard deviation of a luminance distribution of a display in a state of being attached to a surface of the display is a value in a range of 0% to 6%, and a transmission image clarity of a comb width of 0.5mm is a value in a range of 0% to 60%.

Here, the value representing the standard deviation of the luminance distribution of the display indicates the degree of irregularity of the bright spots on the display, and serves as an objective index that can quantitatively evaluate the sharpness of the display. Therefore, in the above configuration, the antiglare layer is configured by setting the standard deviation to a value in the range of 0 to 6, and the glare of the display can be quantitatively evaluated to design the antiglare film. Therefore, an antiglare film which can effectively suppress glare of a display can be stably obtained, compared to, for example, a case where a tester subjectively evaluates glare by visual observation.

Further, by setting the haze value of the antiglare layer to a value in the range of 50% or more and 99% or less while setting the standard deviation to a given value, it is possible to obtain good antiglare properties while suppressing glare of the display. Further, by setting the transmission image clarity of the antiglare film with an optical comb width of 0.5mm to a value in the range of 0% or more and 60% or less, it is possible to widely secure the degree of freedom in designing the transmission image clarity of the antiglare film.

The antiglare layer may include a plurality of resin components and have a co-continuous phase structure formed by phase separation of the plurality of resin components. By using such a co-continuous phase structure, it is possible to easily obtain a good antiglare property while suppressing glare of the display.

The antiglare layer may contain at least one of an acrylic ultraviolet-curable compound containing nano silica and urethane acrylate, an acrylic copolymer, and cellulose acetate propionate. Thus, an antiglare film having antiglare properties and capable of suppressing glare of a display can be easily produced.

The antiglare layer may include a matrix resin, and a plurality of fine particles dispersed in the matrix resin, and a difference in refractive index between the fine particles and the matrix resin may be a value in a range of 0 or more and 0.07 or less.

Thus, the antiglare layer can be formed using the matrix resin and the plurality of fine particles, and an antiglare film having antiglare properties and capable of suppressing glare of a display can be easily manufactured.

A ratio G2/G1 of a weight G1 of the matrix resin of the antiglare layer to a total weight G2 of the plurality of fine particles contained in the antiglare layer may be a value in a range of 0.07 or more and 0.20 or less. Thus, the antiglare film having an antiglare layer having a structure in which a plurality of fine particles are dispersed in a matrix resin can be favorably produced.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the present invention, it is possible to design by quantitatively evaluating the glare of a display, thereby providing an antiglare film having good antiglare properties and capable of suppressing the glare of the display while having a high degree of freedom in design of transmission image clarity.

Drawings

Fig. 1 is a sectional view showing the structure of an antiglare film of embodiment 1.

Fig. 2 is a view showing a method for producing an antiglare film of embodiment 2.

FIG. 3 is a schematic view of a pricking inspection machine.

Description of the symbols

1 anti-glare film

3 anti-glare layer

16a display

Detailed Description

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(embodiment 1)

Fig. 1 is a sectional view showing the structure of an antiglare film 1 of embodiment 1. The antiglare film 1 is attached to the surface of a display 16a of a display device 16 (see fig. 3). The antiglare film 1 includes a base film 2, an antiglare layer 3, and an adhesive layer 4.

The base film 2 is disposed between the display 16a and the antiglare layer 3, and supports the antiglare layer 3. The adhesive layer 4 is disposed between the display 16a and the base film 2, and fixes the antiglare film 1 to the surface of the display 16 a. The adhesive layer 4 is, for example, an optical paste, and is made of a material that does not easily affect the optical properties of the antiglare film 1.

The antiglare layer 3 is formed on at least one surface of the base film 2. The antiglare layer 3 imparts antiglare properties to the antiglare film 1, scatters and reflects external light, and prevents reflection of external light onto the surface of the display 16 a. The antiglare layer 3 also functions as a Hard Coat (HC) layer for protecting the surface of the display 16 a. As one example, the antiglare layer 3 contains a plurality of resin components that can undergo phase separation.

In the state where the antiglare film 1 is attached to the surface of the display 16a, the standard deviation of the luminance distribution of the display 16a is set to a value in the range of 0 or more and 6 or less, and the transmission image clarity of the optical comb width of 0.5mm is set to a value in the range of 0% or more and 60% or less. The haze value of the antiglare layer 3 is set to a value in the range of 50% or more and 99% or less.

The haze value shown in the present embodiment is a value measured by a method based on JIS K7136.

The value of the standard deviation may be appropriately set within the above range, and is preferably a value within a range of 0 to 5.5, and more preferably a value within a range of 0 to 5.0. The value of the transmission image clarity (image clarity) of the optical comb width of 0.5mm may be set as appropriate within the above range, and is preferably a value within a range of 0% to 55%, and more preferably a value within a range of 0% to 50%.

The haze value of the antiglare layer 3 may be appropriately set within the above range, and is preferably a value within a range of 50% to 90%, and more preferably a value within a range of 50% to 85%.

As described above, in the present embodiment, the value of the standard deviation of the luminance distribution of the display 16a indicates the degree of irregularity of the bright points on the display 16a, and becomes an objective index that enables quantitative evaluation of the glare of the display 16a, and based on this, by configuring the antiglare film 1 so that the standard deviation is a value in the range of 0 or more and 6 or less, the glare of the display 16a can be evaluated quantitatively, and the antiglare film 1 can be designed.

Therefore, the antiglare film 1 capable of effectively suppressing the glare of the display 16a can be stably obtained, compared to, for example, a case where a tester subjectively evaluates the glare of the display 16a by visual observation.

Further, by setting the standard deviation of the antiglare film 1 to a given value and setting the haze value of the antiglare layer 3 to a value in the range of 50% or more and 99% or less, it is possible to obtain good antiglare properties while suppressing glare of the display 16 a. Further, by setting the transmission image clarity of the antiglare film 1 with an optical comb width of 0.5mm to a value in the range of 0% or more and 60% or less, it is possible to widely secure the degree of freedom in designing the transmission image clarity of the antiglare film 1.

The antiglare layer 3 of the present embodiment contains a plurality of resin components, and has a co-continuous phase structure formed by phase separation of the plurality of resin components. By using such a co-continuous phase structure, in the antiglare film 1, it is possible to easily obtain a good antiglare property while suppressing glare of the display 16 a.

The antiglare layer 3 of the present embodiment includes an acrylic copolymer, cellulose acetate propionate, and at least one (here, both) of an acrylic ultraviolet-curable compound containing nano silica and a urethane acrylate. This makes it possible to easily manufacture the antiglare film 1 having antiglare properties while suppressing glare of the display 16 a. Specific examples of the base film 2 and the antiglare layer 3 will be described below.

Examples of the material of the base film 2 include glass, ceramics, and resins. As the resin, the same resin as the material of the antiglare layer 3 can be used. Preferable materials of the base film 2 include transparent polymers, for example: cellulose derivatives (e.g., cellulose acetate such as Triacetylcellulose (TAC) or diacetylcellulose), polyester resins (e.g., polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), and polyarylate resins), polysulfone resins (e.g., polysulfone and Polyethersulfone (PES)), polyether ketone resins (e.g., polyether ketone (PEK) and polyether ether ketone (PEEK)), polycarbonate resins (PC), and polyolefin resins (e.g., polyethylene and polypropylene), cyclic polyolefin resins (e.g., ARTON (registered trademark) available from JSR corporation, ZEONEX (registered trademark) available from japan regel corporation), halogen-containing resins (e.g., polyvinylidene chloride), (meth) acrylic resins, styrene resins (e.g., polystyrene), and vinyl acetate or vinyl alcohol resins (e.g., polyvinyl alcohol).

The substrate film 2 may be uniaxially or biaxially stretched, and is preferably an optically isotropic and low-refractive-index film. As the optically isotropic substrate film 2, an unstretched film can be cited.

The thickness of the base film 2 may be appropriately set, and is preferably in the range of 5 μm to 2000 μm, more preferably in the range of 15 μm to 1000 μm, and still more preferably in the range of 20 μm to 500 μm, for example.

[ Structure of antiglare layer ]

The antiglare layer 3 of embodiment 1 has a phase separation structure of a plurality of resin components. As an example, the antiglare layer 3 has a plurality of elongated (string-like or linear) protrusions formed on the surface thereof by a phase separation structure of a plurality of resin components. The elongated projections are branched to form a co-continuous phase structure in a dense state.

The antiglare layer 3 exhibits antiglare properties by a plurality of elongated protrusions and recesses between adjacent elongated protrusions. The antiglare film 1 is provided with the antiglare layer 3, and thus has an excellent balance between a haze value and transmission image clarity (image clarity). The surface of the antiglare layer 3 has a net structure, that is, an irregular multiple-ring structure with continuity or partial deletion, because the elongated projections are formed into a substantially net shape.

The formation of the lenticular (island-like) protrusions on the surface of the antiglare layer 3 can be prevented by the formation of the above-described structure. This prevents the pixels of the display 16a from being viewed in an enlarged manner due to the refraction of the light from the display 16a transmitted through the antiglare layer 3 by the surface irregularities of the antiglare layer 3 or due to the lens effect caused by the surface irregularities of the antiglare layer 3, thereby preventing the glare of the display 16 a. Thus, even when the antiglare film 1 is mounted on the display 16a having high-definition pixels, glare of the display 16a can be highly suppressed while the antiglare property is ensured, and blurring of characters and images and change in color tone can be suppressed.

The plurality of elongated projections may be independent of each other or may be connected together. The phase separation structure of the antiglare layer 3 is formed by spinodal decomposition from a liquid phase (wet spinodal decomposition) using a solution serving as a raw material of the antiglare layer 3, as described below. For details of the antiglare layer 3, reference is made to the description of japanese patent application No. 2012 and 231496, for example.

[ Material of antiglare layer ]

The plurality of resin components included in the antiglare layer 3 may be phase-separable, and preferably include a polymer and a curable resin from the viewpoint of obtaining the antiglare layer 3 having elongated projections and high scratch resistance.

Examples of the polymer contained in the antiglare layer 3 include thermoplastic resins. Examples of the thermoplastic resin include: styrene-based resins, (meth) acrylic resins, organic acid vinyl ester-based resins, vinyl ether-based resins, halogen-containing resins, olefin-based resins (including alicyclic olefin-based resins), polycarbonate-based resins, polyester-based resins, polyamide resins, thermoplastic polyurethane resins, polysulfone resins (polyether sulfone, polysulfone, etc.), polyphenylene ether resins (polymers of 2, 6-xylenol, etc.), cellulose derivatives (cellulose esters, cellulose carbamates, cellulose ethers, etc.), silicone resins (polydimethylsiloxane, polymethylphenylsiloxane, etc.), rubbers or elastomers (diene rubbers such as polybutadiene, polyisoprene, etc., styrene-butadiene copolymers, acrylonitrile-butadiene copolymers, acrylic rubbers, urethane rubbers, silicone rubbers, etc.), and the like. These thermoplastic resins may be used alone or in combination of two or more.

Further, examples of the polymer include a polymer having a functional group participating in a curing reaction or a functional group reactive with a curable compound. The polymer may have a functional group in the main chain or a side chain.

Examples of the functional group include: a condensable group, a reactive group (e.g., a hydroxyl group, an acid anhydride group, a carboxyl group, an amino group, an imino group, an epoxy group, a glycidyl group, an isocyanate group, etc.), a polymerizable group (e.g., a C group such as a vinyl group, a propenyl group, an isopropenyl group, a butenyl group, an allyl group, etc.)_2-6Alkenyl, ethynyl, propynyl, butynyl and the like C_2-6Alkynyl, vinylidene, etc. C_2-6An alkenylene group, a group having such a polymerizable group ((meth) acryloyl group, etc.), and the like. Among these functional groups, polymerizable groups are preferred.

Further, the antiglare layer 3 may contain a plurality of kinds of polymers. The above-mentioned polymers may be phase-separated by spinodal decomposition from a liquid phase, or may be incompatible with each other. The combination of the 1 st polymer and the 2 nd polymer contained in the plurality of kinds of polymers is not particularly limited, and substances incompatible with each other in the vicinity of the processing temperature can be used.

For example, when the 1 st polymer is a styrene-based resin (e.g., polystyrene, styrene-acrylonitrile copolymer), examples of the 2 nd polymer include: cellulose derivatives (e.g., cellulose esters such as cellulose acetate propionate), (meth) acrylic resins (e.g., polymethyl methacrylate), alicyclic olefinic resins (e.g., polymers of norbornene as a monomer), polycarbonate resins, and polyester resins (e.g., poly C)_2-4Alkylene aryl ester copolyesters, etc.).

In addition, for example, in the 1 st polymer is a cellulose derivative (for example, cellulose acetate propionate and other cellulose ester cases), as the 2 nd polymer, can be cited: styrene resin(polystyrene, styrene-acrylonitrile copolymer, etc.), (meth) acrylic resin, alicyclic olefin resin (norbornene-based polymer, etc.), polycarbonate-based resin, polyester-based resin (poly C)_2-4Alkylene aryl ester copolyesters, etc.).

Among the various types of polymers, at least cellulose esters (e.g., cellulose C such as cellulose diacetate, cellulose triacetate, cellulose acetate propionate, and cellulose acetate butyrate) may be contained_2-4Alkyl carboxylic acid esters).

Here, the phase separation structure of the antiglare layer 3 can be fixed by curing a precursor of a curable resin contained in the plurality of resin components by active energy rays (ultraviolet rays, electron beams, or the like), heat, or the like at the time of manufacturing the antiglare layer 3. Further, such a curable resin can impart scratch resistance and durability to the antiglare layer 3.

From the viewpoint of obtaining the scratch resistance of the antiglare layer 3, at least one polymer included in the plurality of types of polymers is preferably a polymer having a functional group reactive with the curable resin precursor in a side chain. The polymer forming the phase separation structure may contain a thermoplastic resin or another polymer in addition to the two mutually incompatible polymers. The weight ratio M1/M2 of the weight M1 of the 1 st polymer to the weight M2 of the 2 nd polymer, and the glass transition temperature of the polymers can be set as appropriate.

Examples of the curable resin precursor include: a curable compound having a functional group that reacts with active energy rays (ultraviolet rays, electron beams, or the like), heat, or the like, and being curable or crosslinkable via the functional group to form a resin (particularly a cured resin or a crosslinked resin).

Examples of such compounds include thermosetting compounds, thermosetting resins (low molecular weight compounds having an epoxy group, a polymerizable group, an isocyanate group, an alkoxysilyl group, a silanol group, or the like (for example, epoxy resins, unsaturated polyester resins, urethane resins, silicone resins, and the like)), and photocurable (ionizing radiation curable) compounds that cure with ultraviolet rays, electron beams, or the like (ultraviolet curable compounds such as photocurable monomers and oligomers).

Preferable examples of the curable resin precursor include photocurable compounds that cure in a short time by ultraviolet rays, electron beams, and the like. Among them, particularly, an ultraviolet-curable compound is practical. In order to improve resistance such as scratch resistance, the photocurable compound preferably has 2 or more (preferably 2 to 15, and more preferably about 4 to 10) polymerizable unsaturated bonds in the molecule. Specifically, the photocurable compound is preferably an epoxy (meth) acrylate, a urethane (meth) acrylate, a polyester (meth) acrylate, a silicone (meth) acrylate, or a polyfunctional monomer having at least 2 polymerizable unsaturated bonds.

The curable resin precursor may contain a curing agent corresponding to the type of the curable resin precursor. For example, the thermosetting resin precursor may contain a curing agent such as an amine or a polycarboxylic acid, and the photocurable resin precursor may contain a photopolymerization initiator. Examples of the photopolymerization initiator include conventional components such as acetophenones, phenylpropanones, benzils, benzoins, benzophenones, thioxanthones, and acylphosphine oxides.

The curable resin precursor may further contain a curing accelerator. For example, the photocurable resin precursor may contain a photocurable accelerator such as a tertiary amine (e.g., dialkyl aminobenzoate) or a phosphine photopolymerization accelerator.

In the process for producing the antiglare layer 3, at least two components of the polymer and the curable resin precursor contained in the solution serving as the raw material of the antiglare layer 3 are used in a combination in which phase separation occurs between them at around the processing temperature. Examples of combinations in which phase separation occurs include: (a) a combination of multiple species of polymers that are mutually incompatible and phase separate; (b) a combination of making the polymer and the curable resin precursor incompatible and phase separating; or (c) a combination of a plurality of curable resin precursors which are mutually incompatible and undergo phase separation. Among these combinations, combinations of (a) a plurality of types of polymers and (b) a polymer and a curable resin precursor are generally mentioned, and combinations of (a) a plurality of types of polymers are particularly preferable.

Here, the polymer and the cured resin or crosslinked resin formed by curing the curable resin precursor generally have refractive indices different from each other. In addition, in general, the refractive indices of a plurality of kinds of polymers (the 1 st polymer and the 2 nd polymer) are also different from each other. The difference in refractive index between the polymer and the cured resin or the crosslinked resin and the difference in refractive index between the plurality of types of polymers (the 1 st polymer and the 2 nd polymer) are, for example, preferably values in the range of 0 to 0.04, and more preferably values in the range of 0 to 0.02.

The antiglare layer 3 may contain a plurality of fine particles (filler) dispersed in the matrix resin. The fine particles may be any of organic fine particles and inorganic fine particles, and the plurality of fine particles may include a plurality of types of fine particles.

Examples of the organic fine particles include crosslinked acrylic acid particles and crosslinked styrene particles. Examples of the inorganic fine particles include silica particles and alumina particles. Further, as an example, the difference in refractive index between the fine particles contained in the antiglare layer 3 and the matrix resin may be set to a value in the range of 0 or more and 0.20 or less. The difference in refractive index is preferably a value in the range of 0 to 0.15, and more preferably a value in the range of 0 to 0.07.

The average particle diameter of the fine particles is not particularly limited, and may be, for example, a value in the range of 0.5 μm or more and 5.0 μm or less. The average particle diameter is preferably a value in the range of 0.5 μm or more and 3.0 μm or less, and more preferably a value in the range of 0.5 μm or more and 2.0 μm or less.

The average particle size referred to herein is a 50% volume average particle size in the coulter counter method (the same applies to the average particle size described below). The particles may be solid or hollow. If the average particle diameter of the fine particles is too small, it is difficult to obtain antiglare properties, and if it is too large, there is a concern that the glare of the display may increase, so attention is required.

The thickness of the antiglare layer 3 can be appropriately set, and is, for example, preferably a value in the range of 0.3 μm or more and 20 μm or less, more preferably a value in the range of 1 μm or more and 15 μm or less, and still more preferably a value in the range of 1 μm or more and 10 μm or less. In general, the value is in the range of 2 μm to 10 μm (particularly, in the range of 3 μm to 7 μm).

The antiglare film in which the base film 2 is omitted may be configured, and in this case, the thickness dimension of the antiglare layer 3 is preferably a value in the range of 1 μm or more and 100 μm or less, and more preferably a value in the range of 3 μm or more and 50 μm or less, for example.

The antiglare layer 3 may contain conventional additives, for example, organic or inorganic particles, stabilizers (antioxidants, ultraviolet absorbers, and the like), surfactants, water-soluble polymers, fillers, crosslinking agents, coupling agents, colorants, flame retardants, lubricants, waxes, preservatives, viscosity modifiers, tackifiers, leveling agents, and defoaming agents, as long as optical characteristics are not impaired.

The method for producing the antiglare film 1 of embodiment 1 includes, as an example, the following steps: a preparation step of preparing a solution (hereinafter, also simply referred to as a solution) to be a raw material of the antiglare layer 3; a forming step of applying the solution prepared in the preparation step to the surface of a predetermined support (in the present embodiment, the substrate film 2), evaporating the solvent in the solution, and forming a phase separation structure by spinodal decomposition from the liquid phase; and a curing step of curing the curable resin precursor after the forming step.

[ preparation Process ]

In the preparation step, a solution containing a solvent, a resin composition for constituting the antiglare layer 3, and predetermined fine particles is prepared. The solvent may be selected according to the type and solubility of the polymer and curable resin precursor contained in the antiglare layer 3. The solvent may be one capable of uniformly dissolving at least the solid components (the various types of polymers and curable resin precursors, the reaction initiator, and other additives).

Examples of the solvent include: ketones (acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, etc.), ethers (di-n-butyl ketone, etc.)

Alkane, tetrahydroFuran, etc.), aliphatic hydrocarbons (hexane, etc.), alicyclic hydrocarbons (cyclohexane, etc.), aromatic hydrocarbons (toluene, xylene, etc.), halogenated carbons (dichloromethane, dichloroethane, etc.), esters (methyl acetate, ethyl acetate, butyl acetate, etc.), water, alcohols (ethanol, isopropanol, butanol, cyclohexanol, etc.), cellosolves (methyl cellosolve, ethyl cellosolve, etc.), cellosolve acetates, sulfoxides (dimethyl sulfoxide, etc.), amides (dimethylformamide, dimethylacetamide, etc.), etc. Further, the solvent may be a mixed solvent.

The resin composition preferably contains the thermoplastic resin, the photocurable compound, the photopolymerization initiator, the thermoplastic resin, and the photocurable compound. Alternatively, the resin composition is preferably a composition containing the mutually incompatible plural kinds of polymers, the photocurable compound, and the photopolymerization initiator.

The concentration of the solute (polymer, curable resin precursor, reaction initiator, and other additives) in the solution can be adjusted within a range in which phase separation of a plurality of resin components occurs and within a range in which the flow property, coating property, and the like of the solution are not impaired.

Here, the haze value of the antiglare layer 3, the transmission image clarity of the antiglare film 1, and the value (glare value) of the standard deviation of the luminance distribution of the display 16a having the antiglare film 1 mounted on the surface thereof vary depending on the combination and weight ratio of the resin composition in the solution, or the working conditions of the production process, the formation process, and the curing process. Therefore, an antiglare film having target physical properties can be obtained by forming an antiglare layer under various conditions and measuring/grasping the physical properties of the obtained antiglare layer in advance.

[ Forming Process ]

In the forming process, the solution prepared in the preparation process is cast or applied to the surface of a support (here, as an example, the base material film 2). Examples of the solution casting method and the solution coating method include conventional methods such as: spray coater, spin coater, roll coater, air knife coater, bar coater, reverse coater, wire bar coater, missing corner wheel coater, dip extrusion coater, die coater, gravure coater, mini gravure coater, screen coater, and the like.

The solvent is evaporated by drying from the solution cast or applied to the surface of the support. As the solution is concentrated during the evaporation, phase separation occurs due to decomposition of a plurality of resin components from the spinodal lines of the liquid phase, and a phase separation structure in which the distance between phases (pitch or mesh diameter) is relatively regular is formed. The co-continuous phase structure of the elongated projections can be formed by setting drying conditions and a compounding ratio that can improve the melt fluidity of the resin component after the solvent evaporation to a certain extent.

The evaporation of the solvent is preferably performed by heat drying, from the viewpoint that the elongated protrusions are easily formed on the surface of the antiglare layer 3. If the drying temperature is too low or the drying time is too short, the heat application to the resin component is insufficient, the melt fluidity of the resin component is reduced, and the formation of elongated projections becomes difficult, and therefore attention is required.

On the other hand, if the drying temperature is too high or the drying time is too long, the temporarily formed elongated protrusions may flow and the height may be lowered, but the structure of the elongated protrusions is maintained. Therefore, as a means for adjusting the antiglare property and the sliding property of the antiglare layer 3 by changing the height of the elongated projections, the drying temperature and the drying time can be used. In the formation step, a co-continuous phase structure in which phase-separated structures are connected to each other can be formed by increasing the evaporation temperature of the solvent or by using a component having low viscosity as the resin component.

When a co-continuous phase structure is formed and coarsened as the phase separation progresses due to the spinodal decomposition of a plurality of resin components from the liquid phase, the continuous phase is discontinuous to form a droplet phase structure (a sea-island structure of an independent phase such as a spherical, disk-like, or ellipsoidal structure). Here, depending on the degree of phase separation, an intermediate structure between the co-continuous phase structure and the droplet phase structure (phase structure in the process of phase transition from the co-continuous phase to the droplet phase) is also formed. After the solvent is removed, a layer having fine irregularities on the surface is formed.

[ curing step ]

In the curing step, the curable resin precursor in the solution is cured, whereby the phase separation structure formed in the forming step is fixed, and the antiglare layer 3 is formed. The curable resin precursor is cured by heating, irradiation with active energy rays, or a combination of these methods, depending on the type of the curable resin precursor. The active energy ray to be irradiated is selected according to the kind of the photocurable component or the like.

The irradiation with the active energy ray may be performed in an inert gas atmosphere. When the active energy ray is ultraviolet ray, as the light source, there can be used: a far ultraviolet lamp, a low pressure mercury lamp, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a halogen lamp, a laser light source (a light source such as a helium-cadmium laser, an excimer laser, etc.), and the like.

In the case of forming the adhesive layer 4, after preparing a solution containing an adhesive component, the solution can be applied and dried on the other surface of the base film 2 by a conventional method, for example, a casting method or a coating method described in the forming step, thereby forming the adhesive layer 4.

Through the above steps, the antiglare film 1 of embodiment 1 can be produced. In the case of using a support having peelability as the support, an antiglare film composed only of the antiglare layer 3 can be obtained by peeling the antiglare layer 3 from the support. In addition, when a non-releasable support (preferably, a transparent support such as the base film 2) is used as the support, the antiglare film 1 having a laminated structure of the support (the base film 2) and the antiglare layer 3 can be obtained.

Here, as a method of suppressing glare of the display 16a, for example, reduction of surface unevenness of the antiglare layer may be considered, but there is a possibility that the antiglare property of the antiglare film is lowered. However, by increasing the number of the unevenness while increasing the inclination of the unevenness of the antiglare layer to steepen the unevenness in addition to reducing the unevenness of the antiglare layer, the antiglare property can be improved while suppressing glare of the display.

In embodiment 1, such irregularities can be formed in the antiglare layer by the above-described spinodal decomposition, and such irregularities can be formed in the antiglare layer by other methods. For example, in the case where a plurality of fine particles are used to form surface irregularities of the antiglare layer as in embodiment 2, by selecting a material so that the repulsive interaction between the fine particles and other resins or solvents is enhanced at the time of formation of the antiglare layer, it is possible to cause appropriate aggregation of the fine particles, and to form a steep and high-number-density distribution structure of the irregularities in the antiglare layer. Therefore, the antiglare layer of another embodiment will be described below centering on differences from embodiment 1.

(embodiment 2)

The antiglare layer of the antiglare film of embodiment 2 includes a matrix resin and a plurality of fine particles dispersed in the matrix resin. The fine particles may be formed into a regular spherical shape, but are not limited thereto, and may be formed into a substantially spherical shape or an elliptical shape. The fine particles may be formed in a solid state or may be formed in a hollow state. In the case where the fine particles are formed to be hollow, the hollow portions of the fine particles may be filled with air or other gas. In the antiglare layer, each fine particle may be dispersed as a primary particle, or a plurality of types of secondary particles formed by aggregating a plurality of fine particles may be dispersed.

The difference in refractive index between the matrix resin and the fine particles is set to a value in the range of 0 to 0.20. The difference in refractive index is more preferably a value in the range of 0 to 0.15, and still more preferably a value in the range of 0 to 0.07.

The average particle diameter of the fine particles is set to a value in the range of 0.5 μm or more and 5.0 μm or less. The average particle diameter of the fine particles is more preferably in the range of 0.5 μm or more and 3.0 μm or less, and still more preferably in the range of 0.5 μm or more and 2.0 μm or less.

Further, the variation in the particle diameter of the fine particles is preferably small, and for example, in the particle diameter distribution of the fine particles contained in the antiglare layer, the average particle diameter of 50 wt% or more of the fine particles contained in the antiglare layer is preferably controlled to be within 1.0 μm.

In this way, by using fine particles having a relatively uniform particle diameter and an average particle diameter set in the above range, uniform and appropriate irregularities can be formed on the surface of the antiglare layer. This can prevent the display 16a from being dazzled while ensuring antiglare properties.

The ratio of the weight of the matrix resin in the antiglare layer to the total weight of the plurality of microparticles can be set as appropriate. In the present embodiment, the ratio G2/G1 of the weight G1 of the matrix resin of the antiglare layer to the total weight G2 of the plurality of fine particles contained in the antiglare layer is a value in the range of 0.07 to 0.20. The ratio G2/G1 is preferably a value in the range of 0.10 or more and 0.20 or less, and more preferably a value in the range of 0.12 or more and 0.20 or less.

The fine particles dispersed in the matrix resin may be inorganic or organic, and preferably have good transparency. Examples of the organic microparticles include plastic beads. Examples of the plastic beads include: styrene beads (refractive index 1.59), melamine beads (refractive index 1.57), acrylic beads (refractive index 1.49), acrylic-styrene beads (refractive index 1.54), polycarbonate beads, polyethylene beads, and the like. The styrene beads may be crosslinked styrene beads and the acrylic beads may be crosslinked acrylic beads. The plastic beads preferably have hydrophobic groups on the surface. Examples of such plastic beads include styrene beads.

Examples of the matrix resin include at least one of a photocurable resin that is cured by an active energy ray, a solvent-drying resin that is cured by drying a solvent added at the time of coating, and a thermosetting resin.

Examples of the photocurable resin include: examples of the resin having an acrylate functional group include oligomers, prepolymers, and reactive diluents such as (meth) acrylates of polyfunctional compounds such as polyester resins, polyether resins, acrylic resins, epoxy resins, urethane resins, alkyd resins, spiro-acetal resins (spiro-acetal resins), polybutadiene resins, polythiol polyene resins, and polyols having relatively low molecular weights.

Specific examples of these include: monofunctional monomers and polyfunctional monomers such as ethyl (meth) acrylate, ethylhexyl (meth) acrylate, styrene, methylstyrene, and N-vinylpyrrolidone, for example, poly (methylolpropane tri (meth) acrylate), hexanediol (meth) acrylate, tripropylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, pentaerythritol tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, 1, 6-hexanediol di (meth) acrylate, and neopentyl glycol di (meth) acrylate.

When the photocurable resin is an ultraviolet curable resin, a photopolymerization initiator is preferably used. Examples of the photopolymerization initiator include: acetophenones, benzophenones, michlebenzylbenzoate, α -amyl oxime ester, tetramethylthiuram monosulfide, thioxanthones. Further, it is also preferable to use a photosensitizer in combination with the photocurable resin. Examples of the photosensitizer include n-butylamine, triethylamine, and poly-n-butylphosphine.

Examples of the solvent-drying resin include known thermoplastic resins. Examples of the thermoplastic resin include: styrene-based resins, (meth) acrylic resins, vinyl acetate-based resins, vinyl ether-based resins, halogen-containing resins, alicyclic olefin-based resins, polycarbonate-based resins, polyester-based resins, polyamide-based resins, cellulose derivatives, silicone-based resins, rubbers or elastomers, and the like. The solvent-drying resin is preferably a resin soluble in an organic solvent, and particularly preferably a resin soluble in an organic solvent and excellent in moldability, film-forming property, transparency and weather resistance. Examples of such a solvent-drying resin include: styrene resins, (meth) acrylic resins, alicyclic olefin resins, polyester resins, and cellulose derivatives (e.g., cellulose esters).

Here, when the material of the base film 2 is a cellulose resin such as Triacetylcellulose (TAC), the thermoplastic resin used for the solvent-drying resin may be a cellulose resin. Examples of the cellulose-based resin include: cellulose derivatives such as nitrocellulose, cellulose acetate, butyl cellulose acetate, ethyl cellulose, methyl cellulose, cellulose acetate propionate, and ethyl hydroxyethyl cellulose. By using a cellulose-based resin as the solvent-drying resin, the base film 2 and the antiglare layer 3 can be favorably adhered to each other, and the antiglare film 1 having excellent transparency can be obtained.

Further, as the solvent drying type resin, there may be mentioned: vinyl resins, acetal resins, acrylic resins, polystyrene resins, polyamide resins, polycarbonate resins, and the like.

Examples of the thermosetting resin include: phenolic resins, urea resins, diallyl phthalate resins, melamine resins, guanamine resins, unsaturated polyester resins, polyurethane resins, epoxy resins, amino alkyd resins, melamine-urea co-condensation resins, silicone resins, polysiloxane resins, and the like. When a thermosetting resin is used as the matrix resin, at least any one of a curing agent such as a crosslinking agent or a polymerization initiator, a polymerization accelerator, a solvent, a viscosity modifier, and the like may be used in combination.

As an example, the method for manufacturing an antiglare film in embodiment 2 includes the steps of: a step of preparing a solution to be a raw material of the antiglare layer 3; a coating step of coating the solution prepared in the preparation step on the surface of a predetermined support (in the present embodiment, the base material film 2); and a curing step of curing the resin in the applied solution.

[ preparation Process ]

In the preparation step, a solution containing a solvent, a resin composition for constituting the antiglare layer, and fine particles is prepared. Examples of the solvent include: alcohols (isopropyl alcohol, methanol, ethanol, etc.), ketones (methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), cyclohexanone, etc.), esters (methyl acetate, ethyl acetate, butyl acetate, etc.), halogenated hydrocarbons, and aromatic hydrocarbons (toluene, xylene, etc.). To the solution, a known leveling agent may be further added. For example, the use of a fluorine-based or silicone-based leveling agent can impart good scratch resistance to the antiglare layer.

[ coating/curing Process ]

In the coating step, the solution prepared in the preparation step is cast or coated on the surface of a support (here, as an example, the base material film 2) by the same method as in embodiment 1. The solvent is removed by evaporation by drying from a solution cast or applied to the surface of the support.

In the case where the base resin is a photocurable resin, after the coating step, as an example, a curing step by ultraviolet rays or electron beams is performed. Examples of the ultraviolet source include: various mercury lamps, ultraviolet carbon arc lamps, black light lamps, and metal halide lamps. The wavelength range of ultraviolet light is, for example, a wavelength range of 190nm to 380 nm.

Further, as the electron beam source, a known electron beam accelerator can be cited. Specifically, there may be mentioned: van der Waals type, Korokhv-Waardon type, resonance transformer type, insulated core transformer type, linear type, high frequency high voltage (Dynamitron) type, high frequency type, and the like.

By curing the matrix resin contained in the solution, the position of the fine particles in the matrix resin can be fixed. This makes it possible to form an antiglare layer having a structure in which a plurality of fine particles are dispersed in a matrix resin and irregularities are formed on the surface of the matrix resin.

According to the antiglare film of embodiment 2, the difference in refractive index between the matrix resin and the fine particles is set to a predetermined range, and the plurality of fine particles are dispersed in the matrix resin, whereby coloring of the antiglare film can be prevented while ensuring good antiglare properties and suppressing glare of the display 16 a.

Further, since the ratio G2/G1 of the antiglare layer is set to a value in the range of 0.07 or more and 0.20 or less, an antiglare film having an antiglare layer in which a plurality of fine particles are dispersed in a matrix resin can be favorably produced.

(embodiment 3)

The antiglare layer 33 of the antiglare film of embodiment 3 has a structure in which a surface on the opposite side to the substrate film side is formed with a concavo-convex shape. The antiglare layer 33 is composed of a resin layer. As an example, the resin layer is formed of the same material as the matrix resin of embodiment 2.

Specifically, the antiglare film of embodiment 3 can be produced by forming a coating layer containing a curable resin on a base film, forming an uneven shape on the surface of the coating layer, and then curing the coating layer. Fig. 2 is a view showing a method for producing an antiglare film of embodiment 3. In the example of fig. 2, an ultraviolet curable resin is used as the curable resin.

As shown in fig. 2, in this manufacturing method, the base film 20a is unwound from a roll not shown and conveyed in a predetermined direction. The downstream end portion in the transport direction of the base material film 20a is inserted into and passes through the nip point N1 between the pair of rollers 21 and 22.

The ultraviolet curable resin precursor adheres to the peripheral surface of the roller 22 from the peripheral surface of a roller 23 that is axially supported adjacent to the roller 22. The ultraviolet curable resin precursor is applied to one side of the base film 20a as the base film 20a passes through the nip point N1.

The layer of the ultraviolet curable resin precursor (hereinafter referred to as a coating layer) applied to the base film 20a is pressed together with the base film 20a at the nip of the rollers 21, 24. The roller 24 is a roller-shaped mold (embossing roller) having fine irregularities formed on the peripheral surface thereof, and when passing through a nip point N2 of the rollers 21 and 24, the irregularities are transferred to the surface of the coating layer.

The coating layer having the uneven shape transferred to the surface by the roller 24 is cured by ultraviolet rays irradiated from an ultraviolet lamp 26 provided below the rollers 21 and 24. Thereby, the antiglare layer 33 can be formed. The antiglare film 33 thus manufactured is released from the roller 24 by the roller 25 which is axially supported adjacent to the roller 24, and is conveyed in a predetermined direction.

Here, the uneven portions on the surface of the roller 24 are formed by hitting shot particles having a predetermined particle diameter by a shot method, and the uneven shape formed on the coating layer of the antiglare film 33 can be adjusted by adjusting the shot particle diameter.

The substrate film 20a may preferably use: PET (polyethylene terephthalate) film, TAC (cellulose triacetate) film, COP (cycloolefin polymer) film, acrylic resin film, polycarbonate resin film.

Thus, the method for producing an antiglare film of embodiment 3 includes the steps of: a step (a) of coating a curable resin precursor on a substrate film; a step (b) of preparing a roll-shaped mold having an uneven surface by beating the shot particles; a step (c) of transferring an uneven shape onto the surface of the curable resin precursor applied to the base film by using the roll mold; and a step (d) of curing the curable resin precursor to which the uneven shape has been transferred to form an antiglare layer having an uneven surface.

The average particle diameter of the sprayed particles used in step (b) may be appropriately set, but may be set to a value in a range of 10 μm or more and 50 μm or less, as an example. The average particle diameter of the ejected particles is more preferably in the range of 20 μm to 45 μm, and still more preferably in the range of 30 μm to 40 μm. This can provide the antiglare layer 33 with the surface having the uneven shape formed thereon.

The mold used in embodiment 3 may be a roll-shaped mold, or may be a plate-shaped mold (embossed plate), for example. Further, after a coating layer (resin layer) is formed on one surface of the base film, the surface of the coating layer is shaped by a mold, and the coating layer is cured to form the antiglare layer 33. In the above examples, the coating layer is cured after the surface of the coating layer is shaped, but the shaping and curing of the coating layer may be performed simultaneously.

Examples of the material of the mold include metal, plastic, and wood. A coating film may be provided on the contact surface of the mold with the coating layer in order to improve the durability (abrasion resistance) of the mold. As an example, the material of the sprayed particles may be metal, silica, alumina, or glass. The ejected particles may strike the surface of the mold, for example, by the pressure of a gas or liquid. In addition, if the cured resin precursor is of an electron beam curing type, an electron beam source such as an electron beam accelerator may be used instead of the ultraviolet lamp 26, and if it is thermosetting, a heat source such as a heater may be used instead of the ultraviolet lamp 26.

In the antiglare film of embodiment 3, since the fine particles can be dispersed in the antiglare layer 33, light incident into the antiglare film is scattered at a wide angle by a difference in refractive index between the matrix resin and the fine particles in the antiglare layer, and the antiglare film can be favorably prevented from being colored.

The antiglare layer of the antiglare film of each of the above embodiments may further include an upper layer disposed on the surface opposite to the substrate film 2 side. By providing this upper layer, the haze value of the antiglare layer can be easily adjusted, and the antiglare film can be easily protected from the outside.

The thickness of the upper layer can be set as appropriate, and can be set to a value in the range of 0.5 μm to 20 μm, for example. The thickness of the upper layer is preferably a value in the range of 2.0 μm or more and 12 μm or less, and more preferably a value in the range of 3.0 μm or more and 8.0 μm or less. Hereinafter, a pricking checker and a pricking evaluation method for checking and evaluating the antiglare film of each of the above embodiments will be described in order.

(dazzling inspection machine)

Fig. 3 is a schematic diagram of the puncture inspection machine 10. The glare tester 10 is a device for evaluating glare of a display 16a in a display device 16 having a film such as an antiglare film attached to a surface thereof, and includes: the image processing apparatus includes a housing 11, an imaging device 12, a holding unit 13, an imaging device holder 14, a display device holder 15, and an image processing device 17. An example of a commercially available pricking inspection machine 10 is a KOMATSU NTC (film pricking inspection machine).

The housing 11 has a dark room for imaging the display 16a by the imaging device 12. The housing 11 houses therein: an imaging device 12, a holding unit 13, an imaging device holder 14, a display device holder 15, and a display device 16 to be evaluated.

As one example, the photographing device 12 is an area camera (area camera) having a lens 18 and a photographing element, which photographs an image displayed on the display 16 a. The imaging device 12 is connected to the image processing device 17, and is held by the holding portion 13 so that the lens 18 faces the display 16 a. The image data captured by the imaging device 12 is sent to the image processing device 17.

The holding portion 13 extends in the vertical direction, and holds the imaging device 12 while its lower end is fixed to the imaging device holder 14. The holding portion 13 holds the imaging device 12 in such a manner that the relative distance between the display 16a and the lens 18 can be changed by relatively moving the imaging device 12 in the vertical direction with respect to the display device 16.

The display device 16 is placed on the display device holder 15 in a state where the film-attached display 16a is opposed to the imaging device 12. The display device holder 15 supports the surface of the display device 16a on which the film is mounted so as to face the imaging device 12 and be horizontal, and relatively moves the display device 16 in a direction perpendicular to the imaging device 12.

In the pricking checker 10, by adjusting the relative distance between the imaging device 12 and the display 16a, the pixel size of an image displayed on the display 16a, which is captured per unit pixel (for example, 1 pixel) of the imaging element of the imaging device 12, can be adjusted.

The image processing device 17 performs data processing of the image data captured by the imaging device 12. Specifically, the image processing device 17 determines a standard deviation of the luminance of the display 16a from the image data captured by the imaging device 12.

The image processing apparatus 17 of the present embodiment includes: an input unit that inputs image data captured by the imaging device 12, an image processing unit that performs image processing on the input image data, and an output unit that outputs the result of the processing performed by the image processing unit to a display device, a printing device, or the like.

As a method for adjusting the pixel size of an image captured per unit pixel (for example, 1 pixel) of an imaging element when an image displayed on the display 16a is captured by the imaging device 12, in addition to a method for changing the relative distance between the imaging device 12 and the display 16a, a method for changing the focal distance of the imaging device 12 may be adopted in a case where the lens 18 provided in the imaging device 12 is a zoom lens.

(evaluation method of eyes)

Next, a method of evaluating a prick using the display 16a of the prick inspection machine 10 will be described. In this glare evaluation method, for the purpose of evaluation, the display 16a having a film mounted on its surface is displayed in advance by uniformly emitting light in a single color (green as an example).

Next, an adjustment step of adjusting the pixel size of the film-mounted display 16a imaged per unit pixel of the imaging element of the imaging device 12 is performed. In the adjusting step, the relative distance between the imaging device 12 and the film-mounted display 16a is adjusted to the following degree according to the effective pixel number of the imaging element of the imaging device 12: so that the absence of bright pixel-based lines in the image captured by the imaging device 12, or the presence of bright pixel-based lines, does not affect the evaluation of the glare of the display 16 a.

The relative distance between the imaging device 12 and the display device 16 is preferably set in consideration of the manner of use of the display device 16 (e.g., the relative distance between the user's eyes and the surface of the display 16 a).

After the adjustment step is performed, a setting step of setting a measurement area for evaluating the glare of the display 16a with the film attached is performed. In the setting step, the measurement area is appropriately set, for example, according to the size of the display 16 a.

After the adjustment step, an imaging step is performed to image the measurement area of the display 16a with the film attached thereto by the imaging device 12. At this time, as an example, at least one of the exposure time of the photographing device 12 or the luminance of the full pixels of the display 16a is adjusted to obtain image data in the form of a gray-scale image displayed in 8-bit gray scale and having an average luminance of 170 gray scales. The image data captured in the capturing step is input to the image processing device 17.

After the image capturing step, the image processing device 17 performs an arithmetic operation for determining the luminance unevenness in the measurement region of the display 16a with the film attached thereto, using the image data. In this calculation step, the luminance unevenness is digitized as a standard deviation of the luminance distribution.

Here, the larger the unevenness in luminance of the film-mounted display 16a, the larger the glare of the film-mounted display 16 a. Accordingly, the smaller the value of the standard deviation of the luminance distribution, the more quantitatively the display 16a can be evaluated as having less glare. In addition, since the adjustment step is performed to such an extent that the bright line of the display 16a with the film attached does not affect the evaluation of the glare of the display 16a, it is possible to suppress the luminance unevenness due to the bright line and perform the accurate glare evaluation of the display 16 a.

Through the above steps, the standard deviation of the luminance distribution of the display 16a having the film mounted on the surface thereof can be obtained, and the glare of the display 16a can be evaluated from the value.

(examples and comparative examples)

The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples.