U.S. patent application number 13/758515 was filed with the patent office on 2013-06-06 for optical film, method for producing the same, polarizing plate and image display device.
This patent application is currently assigned to FUJIFILM Corporation. The applicant listed for this patent is FUJIFILM Corporation. Invention is credited to Miho ASAHI, Kenichi FUKUDA, Katsumi INOUE, Jun WATANABE.
Application Number | 20130143028 13/758515 |
Document ID | / |
Family ID | 40939132 |
Filed Date | 2013-06-06 |
United States Patent
Application |
20130143028 |
Kind Code |
A1 |
ASAHI; Miho ; et
al. |
June 6, 2013 |
OPTICAL FILM, METHOD FOR PRODUCING THE SAME, POLARIZING PLATE AND
IMAGE DISPLAY DEVICE
Abstract
Optical film having a transparent support and optical functional
layer as the outermost layer. The optical functional layer is on or
above the transparent support; has a thickness of 50-250 nm; and
contains low refractive index fine particles having a refractive
index of .ltoreq.1.45 and arranged substantially in a line on a
surface of the optical functional layer on the opposite side of the
transparent support, high refractive index fine particles having a
refractive index of .gtoreq.1.55 and unevenly distributed in a
lower part of the optical functional layer on the side of the
transparent support, and a fluorine-containing compound.
Inventors: |
ASAHI; Miho;
(Minami-Ashigara-shi, JP) ; FUKUDA; Kenichi;
(Minami-Ashigara-shi, JP) ; INOUE; Katsumi;
(Minami-Ashigara-shi, JP) ; WATANABE; Jun;
(Minami-Ashigara-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FUJIFILM Corporation; |
Tokyo |
|
JP |
|
|
Assignee: |
FUJIFILM Corporation
Tokyo
JP
|
Family ID: |
40939132 |
Appl. No.: |
13/758515 |
Filed: |
February 4, 2013 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12370645 |
Feb 13, 2009 |
8389049 |
|
|
13758515 |
|
|
|
|
Current U.S.
Class: |
428/310.5 ;
428/336 |
Current CPC
Class: |
Y10T 428/249961
20150401; G02B 5/3033 20130101; Y10T 428/265 20150115; G02B 1/113
20130101; G02B 1/111 20130101 |
Class at
Publication: |
428/310.5 ;
428/336 |
International
Class: |
G02B 1/11 20060101
G02B001/11 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 13, 2008 |
JP |
P2008-032288 |
Feb 12, 2009 |
JP |
P2009-029706 |
Claims
1. An optical film, comprising: a transparent support; and an
optical functional layer as the outermost layer of the optical
film, the optical functional layer being provided on or above the
transparent support, wherein the optical functional layer has a
thickness of 50 nm or more and not more than 250 nm; the optical
functional layer contains low refractive index fine particles
having a refractive index of not more than 1.45, high refractive
index fine particles having a refractive index of 1.55 or more, and
a fluorine-containing compound; the low refractive index fine
particles are arranged substantially in a line on a surface of the
optical functional layer on the opposite side of the transparent
support; and the high refractive index fine particles are unevenly
distributed in a lower part of the optical functional layer on the
side of the transparent support.
2. The optical film according to claim 1, wherein the optical
functional layer contains the low refractive index fine particles
in a range of from 5% by mass to 15% by mass with respect to the
entire solid content of the optical functional layer.
3. The optical film according to claim 1, wherein the optical
functional layer contains the high refractive index fine particles
in a range of from 30% by mass to 50% by mass with respect to the
entire solid content of the optical functional layer.
4. The optical film according to claim 1, wherein the low
refractive index fine particles are silica fine particles or hollow
silica fine particles.
5. The optical film according to claim 1, wherein a ratio of
[(P.sub.Lu/P.sub.Lt).times.100] is 200% or more, in which P.sub.Lt
represents an average particle packing factor of the low refractive
index fine particles in the whole layer of the optical functional
layer; and P.sub.Lu represents an average particle packing factor
of the low refractive index fine particles in the 30% thickness in
an upper part of the optical functional layer on the opposite side
of the transparent support.
6. The optical film according to claim 1, wherein a ratio of
[(P.sub.Hd/P.sub.Ht).times.100] is 120% or more, in which P.sub.Ht
represents an average particle packing factor of the high
refractive index fine particles in the whole layer of the optical
functional layer; and P.sub.Hd represents an average particle
packing factor of the high refractive index fine particles in the
50% thickness in a lower part of the optical functional layer on
the side of the transparent support.
7. The optical film according to claim 1, wherein the low
refractive index fine particles are surface-modified with a
fluorine atom-free silane coupling agent.
8. The optical film according to claim 1, wherein the high
refractive index fine particles are oxide fine particles of at
least one element selected from the group consisting of aluminum,
zirconium, titanium, zinc, germanium, indium, tin, antimony and
cerium.
9. A polarizing plate, comprising: the optical film according to
claim 1 as a protective film for the polarizing plate.
10. An image display device, comprising: the optical film according
to claim 1.
11-16. (canceled)
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an optical film, a method
for producing the same, a polarizing plate and an image display
device.
[0003] 2. Description of the Related Art
[0004] In various image display devices, for example, a liquid
crystal display device (LCD), a plasma display panel (PDP), an
organic EL display (OLED), a cathode ray tube display device (CRT),
etc., an antireflection film is disposed on the surface of the
display for the purpose of preventing reflection of external light
or a lowering of contrast due to reflection of an image. For that
reason, the antireflection film is required to have high physical
strengths (for example, scratch resistance, etc.), transmittance,
chemical resistance, weather resistance and the like in addition to
high antireflection properties.
[0005] In particular, an antireflection film with high
antireflection properties is desired for the purposes of preventing
the reflection of external light and enhancing the image quality in
an image display device. There has hitherto been employed a method
of providing an optical functional layer (optical interference
layer) on a hard coat layer formed on a plastic substrate. In order
to realize higher antireflection properties, it is known to be
effective to stack plural optical functional layers. However, in
order to realize this by a wet coating process, it is necessary to
repeat steps of coating, drying and curing several times; and thus,
not only the productivity is remarkably lowered, but the coating
cost increases. For example, when two layers of a low refractive
index layer and a high refractive index layer are stacked as the
optical functional layer, repetition of two times is necessary. In
the case of additionally coating a middle refractive index layer
for the purpose of further reducing the reflectance, repetition of
three times is necessary. Accordingly, a technology for forming
plural layers by single coating is eagerly desired.
[0006] In order to prevent the reflection of external light, a
method of reducing the reflectance by providing a layer having a
low refractive index as far as possible is also effective. As a
method of reducing the refractive index of a layer, there is known
a method of introducing a fluorine atom or introducing an inorganic
fine particle having a hollow structure in the inside thereof.
However, according to all of these methods, there is a tendency in
which the coating strength and adhesion are impaired and the
scratch resistance is lowered. Thus, it was difficult to make both
low refractive index and high scratch resistance compatible with
each other.
[0007] As a method for solving this problem, JP-A-2006-235198
proposes an optical film including a support having thereon an
optical functional layer prepared by coating a composition
containing a fine particle and a binder, wherein an SP value which
is a ratio of an average particle packing factor (B) in the 30%
thickness on the upper layer side on the opposite side to the
support to an average particle packing factor (A) in the whole
layer of the optical functional layer [(B/A).times.100] is 90% or
more and not more than 333%.
[0008] Also, JP-A-2007-238897 discloses a curable resin composition
containing (A) a metal oxide particle having (Ab) a polymerizable
unsaturated group-containing organic compound bound thereto; (B) an
ethylenically unsaturated group-containing fluorine-containing
polymer; (C) a particle composed of as a major component, silica
having (Cb) an alkoxysilyl group-containing fluorine-containing
polymer bound thereto; (D1) a solvent having high solubility
against the ethylenically unsaturated group-containing
fluorine-containing polymer (B); and (D2) a solvent having a lower
relative evaporation rate than the solvent (D1) and having
compatibility with the solvent (D1). According to the technology of
JP-A-2007-238897, it is mentioned that two or more layers can be
formed from a single coating film obtained by coating the subject
curable resin composition.
[0009] However, the cured film obtained according to the technology
of JP-A-2007-238897 involves a problem that the scratch resistance
is still insufficient.
SUMMARY OF THE INVENTION
[0010] It is important that an antireflection film also serves as a
protective film because it is disposed on the outermost surface of
an image display device; and the antireflection film is required to
have high physical strengths. In order to realize these matters, it
is important that a low refractive index fine particle exists in a
high density on the outermost surface. Similarly, in the
development, it is required that regulation with a high degree of
freedom can be achieved such that the refractive index and the
thickness of the high refractive index layer can be arbitrarily
changed. If it would be possible to make all of the high refractive
index fine particles maldistributed on the side of the support,
such regulation will become easy, and it will be able to be
expected that the degree of freedom regarding the kind of the high
refractive index fine particle or the regulation of the coating
composition is increased.
[0011] Furthermore, the development of an optical film capable of
forming an optical functional layer in which the low refractive
index fine particle is disposed on the outermost surface by coating
in a small number of times as far as possible, for example, one
time, and a method for producing the same are eagerly desired.
[0012] An object of the invention is to provide an optical film
which is high in antireflection properties, excellent in scratch
resistance and suitable for mass production and a method for
producing the same. Another object of the invention is to provide a
polarizing plate and an image display device, each of which is
provided with the subject optical film.
[0013] As a result of extensive and intensive investigations, the
present inventors have found that the foregoing problems can be
attained by the following measures.
[0014] (1) An optical film, comprising: [0015] a transparent
support; and [0016] an optical functional layer as the outermost
layer of the optical film, the optical functional layer being
provided on or above the transparent support, [0017] wherein the
optical functional layer has a thickness of 50 nm or more and not
more than 250 nm; [0018] the optical functional layer contains low
refractive index fine particles having a refractive index of not
more than 1.45, high refractive index fine particles having a
refractive index of 1.55 or more, and a fluorine-containing
compound; [0019] the low refractive index fine particles are
arranged substantially in a line on a surface of the optical
functional layer on the opposite side of the transparent support;
and [0020] the high refractive index fine particles are unevenly
distributed in a lower part of the optical functional layer on the
side of the transparent support.
[0021] (2) The optical film as described in (1) above, [0022]
wherein the optical functional layer contains the low refractive
index fine particles in a range of from 5% by mass to 15% by mass
with respect to the entire solid content of the optical functional
layer.
[0023] (3) The optical film as described in (1) or (2) above,
[0024] wherein the optical functional layer contains the high
refractive index fine particles in a range of from 30% by mass to
50% by mass with respect to the entire solid content of the optical
functional layer.
[0025] (4) The optical film as described in any of (1) to (3)
above, [0026] wherein the low refractive index fine particles are
silica fine particles or hollow silica fine particles.
[0027] (5) The optical film as described in any of (1) to (4)
above, [0028] wherein a ratio of [(P.sub.Lu/P.sub.Lt).times.100] is
200% or more, [0029] in which P.sub.Lt represents an average
particle packing factor of the low refractive index fine particles
in the whole layer of the optical functional layer; and [0030]
P.sub.Lu, represents an average particle packing factor of the low
refractive index fine particles in the 30% thickness in an upper
part of the optical functional layer on the opposite side of the
transparent support.
[0031] (6) The optical film as described in any of (1) to (5)
above, [0032] wherein a ratio of [(P.sub.Hd/P.sub.Ht).times.100] is
120% or more, [0033] in which P.sub.Ht represents an average
particle packing factor of the high refractive index fine particles
in the whole layer of the optical functional layer; and [0034]
P.sub.Hd represents an average particle packing factor of the high
refractive index fine particles in the 50% thickness in a lower
part of the optical functional layer on the side of the transparent
support.
[0035] (7) The optical film as described in any of (1) to (6)
above, [0036] wherein the low refractive index fine particles are
surface-modified with a fluorine atom-free silane coupling
agent.
[0037] (8) The optical film as described in any of (1) to (7)
above, [0038] wherein the high refractive index fine particles are
oxide fine particles of at least one element selected from the
group consisting of aluminum, zirconium, titanium, zinc, germanium,
indium, tin, antimony and cerium.
[0039] (9) A polarizing plate, comprising: [0040] the optical film
as described in any of (1) to (8) above as a protective film for
the polarizing plate.
[0041] (10) An image display device, comprising: [0042] the optical
film as described in any of (1) to (8) above or the polarizing
plate as described in (9) above.
[0043] (11) A method for producing an optical film that includes a
transparent support and an optical functional layer as the
outermost layer of the optical film, the method comprising: [0044]
applying a curable composition directly or indirectly on the
transparent support, the curable composition containing low
refractive index fine particles having a refractive index of not
more than 1.45, high refractive index fine particles having a
refractive index of 1.55 or more, and a fluorine-containing
compound; and [0045] curing the curable composition to form an
optical functional layer having a thickness of 50 nm or more and
not more than 250 nm, [0046] wherein in the optical functional
layer, the low refractive index fine particles are arranged
substantially in a line on a surface of the optical functional
layer on the opposite side of the transparent support; and [0047]
the high refractive index fine particles are unevenly distributed
in a lower part of the optical functional layer on the side of the
transparent support.
[0048] (12) A method for producing an optical film that includes a
transparent support and an optical functional layer as the
outermost layer of the optical film, the method comprising: [0049]
applying curable compositions 1 and 2 directly or indirectly on the
transparent support by using a coating device that includes at
least one member selected from the group consisting of adjacent two
slot dies and a slide-type coating head while supporting the
transparent support by backup rollers and traveling the transparent
support, [0050] the curable composition 1 containing low refractive
index fine particles having a refractive index of not more than
1.45 and a fluorine-containing compound, [0051] the curable
composition 2 containing high refractive index fine particles
having a refractive index of 1.55 or more; and [0052] curing the
curable compositions 1 and 2 to form an optical functional layer
having a thickness of 50 nm or more and not more than 250 nm,
[0053] wherein in the optical functional layer, the low refractive
index fine particles are arranged substantially in a line on a
surface of the optical functional layer on the opposite side of the
transparent support; and [0054] the high refractive index fine
particles are unevenly distributed in a lower part of the optical
functional layer on the side of the transparent support.
[0055] (13) The method as described in (11) or (12) above, [0056]
wherein the low refractive index fine particles are silica fine
particles or hollow silica fine particles.
[0057] (14) The method as described in any of (11) to (13) above,
[0058] wherein the low refractive index fine particles are
surface-modified with a fluorine atom-free silane coupling
agent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] FIG. 1 is a cross-sectional view of an exemplary embodiment
of an optical film of the invention;
[0060] FIG. 2 is a cross-sectional view of another exemplary
embodiment of an optical film of the invention;
[0061] FIG. 3 is a cross-sectional view of another exemplary
embodiment of an optical film of the invention;
[0062] FIG. 4 is a cross-sectional view schematically showing a
layer configuration of a two-layer type optical film as another
exemplary embodiment of an optical film of the invention; and
[0063] FIG. 5 is a cross-sectional view schematically showing a
layer configuration of a multilayer type optical film as another
exemplary embodiment of an optical film of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0064] The invention is hereunder described. In this specification,
the term "(meth)acrylate" refers to "at least one of acrylate and
methacrylate". The term "(meth)acrylic acid" or the like is also
the same. Furthermore, the terms "on the support" as referred to in
the invention include both the case of "directly on the surface of
the support" and the case of "on the surface via any layer (film)
on the support".
[0065] The invention is concerned with an optical film in which an
optical functional layer formed in the most surficial layer on a
transparent support contains (A) a low refractive index fine
particle having a refractive index of not more than 1.45, (B) a
high refractive index fine particle having a refractive index of
1.55 or more and (C) a fluorine-containing compound; the low
refractive index fine particle (A) is arranged substantially in a
line on the surface of the optical functional layer on the opposite
side of the transparent support; and the high refractive index fine
particle (B) is maldistributed (unevenly distributed) in a lower
part of the optical functional layer on the side of the transparent
support. When the optical functional layer takes the foregoing
structure, an antireflection layer configured of two layers of a
low refractive index layer and a high refractive index layer is
seemingly formed, and when the low refractive index fine particle
is arranged in a line on the surface, the resulting optical film is
excellent in scratch resistance. Furthermore, according to the
invention, since the optical functional layer having the foregoing
structure is formed by single coating, the invention is excellent
in productivity.
[0066] In this specification, a layer having physical and optical
functions, which is formed on the transparent support, is also
referred to as "functional layer". In the optical film of the
invention, the optical functional layer may serve as plural
functional layers. Also, the optical film of the invention can have
other functional layer as the need arises.
[0067] In the optical film of the invention, in the optical
functional layer formed as the most surficial layer on the
transparent support, the low refractive index fine particle is
arranged substantially in a line on the outermost surface of the
optical functional layer. The terms "arranged substantially in a
line on the outermost surface of the optical functional layer" as
referred to herein refer to the state in which when a cross section
of the film is observed, a half or more of the low refractive index
fine particle is arranged substantially in parallel on the
outermost surface of the optical functional layer. This also
includes those existing on the outermost surface of the optical
functional layer, those covered by a binder and those in which a
part of the particle is slightly projected from the surface. Also,
there may be the case where the fine particle exists in the second
line on the outermost surface. The case where a proportion of the
fine particle existing in the first line is higher than that of
those existing in the second line is considered to be included in
the aspect that the fine particle is arranged substantially in a
line in the invention.
[0068] The outermost surface of the optical functional layer refers
to a region of from the farthest side from the support of the
optical functional layer to a depth of two times the average
particle size of the low refractive index fine particle. Also, in
the optical functional layer, a region where the high refractive
index fine particle is distributed is called the high refractive
index layer; and even when the low refractive index fine particle
is mixed in the region where the high refractive index fine
particle is distributed, such a region is also called the high
refractive index layer. A region other this region is called the
low refractive index layer. The case where the high refractive
index fine particle is not maldistributed but distributed over the
whole of the optical functional layer is defined such that the high
refractive index layer is absent.
[0069] The invention is further described with reference to FIG.
1.
[0070] FIG. 1 is a cross-sectional diagrammatic view of an
embodiment of the optical film of the invention.
[0071] An optical film 1 of the invention has an optical functional
layer 12 on the outermost surface on a transparent support 1, and
it is preferable that a high refractive index fine particle 122 is
maldistributed on the side of the optical functional layer 12
coming into contact with the transparent support 11, whereas a low
refractive index fine particle 121 is densely spread over the
surface of the optical functional layer 12 on the opposite side to
the surface coming into contact with the transparent support 11. An
arbitrary functional layer may be provided between the optical
functional layer 12 and the transparent support 11.
[0072] FIGS. 2 and 3 are each a cross-sectional view of another
embodiment of the optical film of the invention. As shown in FIG.
2, it is not necessary that the entire surface of the optical
functional layer 12 is configured of the low refractive index fine
particle 121. Also, as shown in FIG. 3, the low refractive index
fine particle 121 may be superimposed in plural while densely
spreading the low refractive index fine particle 121.
[0073] Raw materials constituting the optical functional layer are
hereunder described in more detail.
[0074] In order to form the optical functional layer of the optical
film of the invention, which has a specified structure, a
fluorine-containing compound, a low refractive index fine particle
and a high refractive index fine particle are an essential
component. The fluorine-containing compound is hardly miscible with
others and has properties that compounds having the same structure
are liable to gather each other. Accordingly, it may be considered
that when these essential components are mixed and coated, the
fluorine-containing compound works to cause cohesion and to remove
the low refractive index fine particle and the high refractive
index fine particle. As a result, these fine particles are
maldistributed on the uppermost surface side or the support side.
At that time, for the purpose of taking a more thermally stable
structure, a fine particle with relatively low surface energy is
displaced onto the uppermost surface side, whereas a fine particle
with relatively high surface energy is displaced onto the support
side. The low refractive index fine particle has lower surface
energy than the high refractive index fine particle, and the low
refractive index fine particle is added in an amount at which it
can exist on the uppermost surface. As a result, it may be
considered that it has become possible to form the optical
functional layer structure of the invention.
<(C) Fluorine-Containing Compound>
[0075] The optical film of the invention contains (C) a
fluorine-containing compound. The fluorine-containing compound (C)
is preferably formed of a thermally curable or photocurable
fluorine-containing compound (C1). The thermally curable or
photocurable fluorine-containing compound (C1) is preferably a
fluorine-containing compound having a silicone structure in a
molecule thereof, or containing a silicone compound in which a
coating composition for forming an optical functional layer
contains a crosslinking group, and having the same crosslinking
group as the subject crosslinking group.
[0076] Also, surface free energy of (C) the fluorine-containing
compound is preferably in the range of not more than 35 mN/m, and
more preferably in the range of not more than 30 mN/m. By making
the surface free energy of (C) the fluorine-containing compound
fall within the foregoing range, cohesion between (C) the
fluorine-containing compounds increases so that the layer
separation can effectively occur. On the other hand, when the
surface free energy after curing is too high, the layer separation
hardly occurs, thereby possibly causing an increase of the
reflectance, unevenness, etc. The surface free energy is preferably
controlled to not higher than the foregoing preferred upper limit
from the viewpoints of strength and coating properties.
[0077] The layer separation as referred to in the invention refers
to the state in which the low refractive index fine particle is
arranged substantially in a line on the surface of the optical
functional layer, the high refractive index fine particle is
maldistributed in a lower part of the optical functional layer, and
the both fine particles are substantially separated from each
other.
[0078] As to the examples of the thermally curable or photocurable
fluorine-containing compound (C1) include a fluorine-containing
monomer, oligomer or polymer and a fluorine-containing sol-gel raw
material, each having a crosslinking or polymerizable functional
group. It is preferable that such a compound is crosslinked with
heat or ionizing radiations. A raw material having such properties
that the surface of the optical functional layer formed therefrom
has a coefficient of dynamic friction of from 0.03 to 0.30 and a
contact angle against water of from 85 to 120.degree. is
preferable.
[Fluorine-Containing Polymer]
[0079] The above fluorine-containing polymer which is suitable for
the fluorine-containing compound having a crosslinking or
polymerizable functional group is a fluorine-containing polymer
which is crosslinked with heat or ionizing radiations, and such a
fluorine-containing polymer is preferable from the standpoint of
enhancing the productivity in the case of coating and curing while
web delivering a roll film or other cases. The fluorine-containing
polymer is more preferably a fluorine-containing polymer which is
crosslinked with ionizing radiations from the standpoint of
productivity; and especially preferably a fluorine-containing
polymer having plural ethylenically unsaturated groups as a
crosslinking group in a molecule thereof from the standpoints of
productivity and scratch resistance.
[0080] Examples of the fluorine-containing polymer include
copolymers of a fluorine-containing monomer and a monomer having a
crosslinking or polymerizable functional group. Examples of the
fluorine-containing monomer include fluoroolefins (for example,
fluoroethylene, vinylidene fluoride, tetrafluoroethylene,
hexafluoroethylene, hexafluoropropylene,
perfluoro-2,2-dimethyl-1,3-dioxole, etc.); partially or completely
fluorinated alkyl ester derivatives of (meth)acrylic acid (for
example, BISCOAT 6FM (manufactured by Osaka Organic Chemical
Industry Ltd.), M-2020 (manufactured by Daikin Industries, Ltd.),
etc.); and completely or partially fluorinated vinyl ethers.
[0081] In an embodiment, examples of the monomer for imparting a
crosslinking group include (meth)acrylate monomers having a
crosslinking functional group in advance in a molecule thereof,
such as glycidyl methacrylate. In another embodiment, there is a
method of using a monomer in which a fluorine-containing copolymer
is synthesized using a monomer having a functional group such as a
hydroxyl group, and such a substituent is then further modified to
introduce a crosslinking or polymerizable functional group.
Examples of such a monomer include (meth)acrylate monomers having a
carboxyl group, a hydroxyl group, an amino group, a sulfonic acid
group, etc. (for example, (meth)acrylic acid,
methylol(meth)acrylate, hydroxyalkyl(meth)acrylates, allyl
acrylate, etc.). The latter embodiment is disclosed in
JP-A-10-25388 and JP-A-10-147739.
[0082] A fluorine-containing compound having crosslinking
properties can also be used. A compound having a fluoroalkyl group
is preferable as the fluorine-containing compound. The fluoroalkyl
group has preferably from 1 to 20 carbon atoms, and more preferably
from 1 to 10 carbon atoms. The fluoroalkyl group may have a linear
structure (for example, --CF.sub.2CF.sub.3,
--CH.sub.2(CF.sub.2).sub.4H, --CH.sub.2(CF.sub.2).sub.8CF.sub.3,
--CH.sub.2CH.sub.2(CF.sub.2).sub.4H, etc.), a branched structure
(for example, CH(CF.sub.3).sub.2, CH.sub.2CF(CF.sub.3).sub.2,
CH(CH.sub.3)CF.sub.2CF.sub.3,
CH(CH.sub.3)(CF.sub.2).sub.5CF.sub.2H, etc.) or an alicyclic
structure (preferably a 5-membered ring or a 6-membered ring; for
example, a perfluorocyclohexyl group, a perfluorocyclopentyl group,
an alkyl group substituted with such a group, etc.), or may have an
ether bond (for example, CH.sub.2OCH.sub.2CF.sub.2CF.sub.3,
CH.sub.2CH.sub.2OCH.sub.2C.sub.4F.sub.8H,
CH.sub.2CH.sub.2OCH.sub.2CH.sub.2C.sub.8F.sub.17,
CH.sub.2CH.sub.2OCF.sub.2CF.sub.20CF.sub.2CF.sub.2H, etc.). A
plural number of the fluoroalkyl group may be contained in the same
molecule.
[0083] Examples of the crosslinking group include an acryloyl
group, a methacryloyl group, a vinyl group, an allyl group, a
cinnamoyl group, an epoxy group, an oxetanyl group, a hydroxyl
group, a polyoxyalkylene group, a carboxyl group and an amino
group. The fluorine based compound may be a copolymer with a
fluorine atom-free compound or an oligomer. Its molecular weight is
not particularly limited. Though the content of a fluorine atom of
the fluorine-containing compound is not particularly limited, it is
preferably 20% by mass or more, especially preferably from 30 to
70% by mass, and most preferably from 40 to 70% by mass. (In this
specification, mass ratio is equal to weight ratio.) Preferred
examples of such a fluorine-containing compound having a
crosslinking group include R-2020, M-2020, R-3833 and M-3833 (all
of which are a trade name, manufactured by Daikin Industries,
Ltd.); and MEGAFAC F-171, MEGAFAC F-172, MEGAFAC F-179A and DEFENSA
MCF-300 (all of which are a trade name, manufactured by DIC
Corporation). However, it should not be construed that the
invention is limited thereto.
[0084] The foregoing fluorine-containing polymer can properly
contain a copolymerizable component from the viewpoints of
solubility, dispersibility, coating properties, antifouling
properties, antistatic properties and the like. In particular, in
order to impart antifouling properties and slipperiness, it is
preferred to introduce a silicone structure, and the silicone can
be introduced into any of a principal chain and a side chain.
[0085] Examples of a method of introducing a silicone structure
into a principal chain include a method of using a polymer type
initiator such as an azo group-containing polysiloxane amide
described in JP-A-6-93100 (examples of commercially available
materials include VPS-0501 and VPS-1001 (trade names; manufactured
by Wako Pure Chemical Industries, Ltd.)).
[0086] Also, as to a method of introducing a polysiloxane partial
structure into a side chain, the synthesis can be achieved by a
method of introducing a polysiloxane having a reactive group in one
terminal end thereof (for example, SILAPRENE Series (manufactured
by Chisso Corporation), etc.) through a polymer reaction, or a
method of polymerizing a polysiloxane-containing silicon macromer
described in J. Appl. Polym. Sci., 2000, 78, 1955, JP-A-56-28219,
etc. The both methods can be preferably adopted.
[0087] The fluorine-containing polymer may be properly used in
combination with a curing agent having a polymerizable unsaturated
group described in JP-A-2000-17028. It is also preferable to use
the foregoing polymer in combination with a fluorine-containing
polyfunctional compound having a polymerizable unsaturated group
described in JP-A-2002-145952. Examples of the polyfunctional
compound having a polymerizable unsaturated group include monomers
having two or more of the foregoing ethylenically unsaturated
groups. A hydrolysis condensate of an organosilane described in
JP-A-2004-170901 is also preferable, and a hydrolysis condensate of
a (meth)acryloyl group-containing organosilane is especially
preferable.
[0088] In particular, in the case of using a compound having a
polymerizable unsaturated group in a fluorine-containing polymer
main body, such a compound is preferable because an effect to be
brought by the combined use against the improvement of scratch
resistance is large.
[0089] In the case where a fluorine-containing polymer itself does
not have sufficient curing properties alone, necessary curing
properties can be imparted by blending a crosslinking compound. For
example, in the case where a fluorine-containing polymer main body
contains a hydroxyl group, it is preferred to use various amino
compounds as a curing agent. Examples of the amino compound which
is used as the crosslinking compound include compounds having two
or more in total of either one or both of a hydroxyalkylamino group
and an alkoxyalkylamino group. Specific examples thereof include
melamine based compounds, urea based compounds, benzoguanamine
based compounds and glycoluril based compounds. It is preferred to
use an organic acid or a salt thereof for curing such a
compound.
[0090] Specific examples of such a fluorine-containing polymer are
described in JP-A-2003-222702, JP-A-2003-183322, etc.
{Hydrolysis Condensate of Fluorine-Containing Organosilane
Material}
[0091] A hydrolysis condensate of a fluorine-containing
organosilane compound can also be preferably used as the
fluorine-containing compound having a crosslinking group from the
standpoint that it is low in refractive index and high in hardness
of a coating film surface. A condensate of a compound containing a
hydrolyzable silanol at one terminal end or both terminal ends
relative to a fluorinated alkyl group and a tetraalkoxysilane is
preferable. Specific compositions are described in JP-A-2002-265866
and JP-A-2002-317152.
[0092] As described above, it is preferable that a
fluorine-containing compound which is suitable as the
fluorine-containing compound having a crosslinking group has a
silicone structure in a molecule thereof. A silicone compound
having the same crosslinking group as in the fluorine-containing
compound may be contained in the coating composition.
[0093] Examples of the silicone compound include the following
compounds.
[0094] Examples of the silicone compound having a crosslinking
group include compounds containing plural dimethylsilyloxy units as
a repeating unit and containing a substituent in a terminal end
and/or a side chain of the chemical chain thereof. A structural
unit other than dimethylsilyloxy may be contained in the chemical
chain containing dimethylsilyloxy as a repeating unit. The
substituent may be the same or different, and it is preferable that
plural substituents are contained. Preferred examples of the
substituent include groups containing, for example, an acryloyl
group, a methacryloyl group, a vinyl group, an aryl group, a
cinnamoyl group, an epoxy group, an oxetanyl group, a hydroxyl
group, a fluoroalkyl group, a polyoxyalkylene group, a carboxyl
group, an amino group, etc. Though the molecular weight is not
particularly limited, it is preferably not more than 100,000, more
preferably not more than 50,000, especially preferably from 3,000
to 30,000, and most preferably from 10,000 to 20,000. Though the
content of a silicon atom of the silicone compound is not
particularly limited, it is preferably 18.0% by mass or more,
especially preferably from 25.0 to 37.8% by mass, and most
preferably from 30.0 to 37.0% by mass. Preferred examples of the
silicone compound include X-22-174DX, X-22-2426, X-22-164B,
X22-164C, X-22-170DX, X-22-176D and X-22-1821 (all of which are a
trade name, manufactured by Shin-Etsu Chemical Co., Ltd.); FM-0725,
FM-7725, FM-4421, FM-5521, FM-6621 and FM-1121 (all of which are
manufactured by Chisso Corporation); and DMS-U22, RMS-033, RMS-083,
UMS-182, DMS-H21, DMS-H31, HMS-301, FMS121, FMS123, FMS131, FMS141
and FMS221 (all of which are a trade name, manufactured by Gelest,
Inc.). However, it should not be construed that the invention is
limited thereto.
[0095] The addition amount of the silicone compound is preferably
in the range of from 0.01 to 20% by mass, more preferably in the
range of from 0.05 to 10% by mass, and especially preferably in the
range of from 0.1 to 7% by mass relative to the fluorine-containing
compound.
<Curable Compound>
[0096] In the coating composition for forming the optical
functional layer of the optical film of the invention, a curable
compound which is curable with the fluorine-containing compound
having a crosslinking group may be contained. As a preferred
example of the curable compound, monomers or oligomers having a
reactive group which is crosslinked with heat or ionizing
radiations are preferable; resin components having a polyfunctional
monomer or a polyfunctional oligomer each having two or more
functional groups are more preferable; and resin components having
a polyfunctional monomer or a polyfunctional oligomer each having
three or more functional groups are further preferable. Such a
polyfunctional monomer or oligomer is also preferably incorporated
in the functional layer. Also, two or more kinds of the
polyfunctional monomer may be used in combination.
[0097] It is preferable that the curable compound has larger
surface free energy than the fluorine-containing compound. A resin
capable of forming a cured layer having surface free energy of 35
mN/m or more is preferable. The surface free energy is more
preferably in the range of from 35 to 80 mN/m, and especially
preferably in the range of from 40 to 60 mN/m.
[0098] By making the surface free energy fall with the foregoing
range, it is easy to achieve the layer separation. Even when the
surface free energy after curing is excessively high or excessively
low, a lowering of reflectance, unevenness, etc. may be possibly
generated. The surface free energy is preferably controlled to the
foregoing preferred lower limit or higher from the viewpoints of
strength and coating properties.
[0099] As the functional group of the ionizing radiation curable
polyfunctional monomer or polyfunctional oligomer, photo, electron
beam or ionizing radiation polymerizable functional groups are
preferable. Above all, photopolymerizable functional groups are
preferable.
[0100] Specific examples of the photopolymerizable functional group
include unsaturated polymerizable functional groups such as a
(meth)acryloyl group, a vinyl group, a styryl group, and an allyl
group, with a (meth)acryloyl group being preferable.
[0101] Specific examples of the photopolymerizable polyfunctional
monomer having a photopolymerizable functional group include:
[0102] (meth)acrylic diesters of an alkylene glycol such as
neopentyl glycol acrylate, 1,6-hexanediol(meth)acrylate and
propylene glycol di(meth)acrylate; [0103] (meth)acrylic diesters of
a polyoxyalkylene glycol such as triethylene glycol
di(meth)acrylate, dipropylene glycol di(meth)acrylate, polyethylene
glycol di(meth)acrylate and polypropylene glycol di(meth)acrylate;
[0104] (meth)acrylic diesters of a polyhydric alcohol such as
pentaerythritol di(meth)acrylate; and [0105] (meth)acrylic diesters
of an ethylene oxide or propylene oxide adduct such as
2,2-bis{4-(acryloxy.diethoxy)phenyl}propane and
2,2-bis{4-(acryloxy.polypropoxy)phenyl}propane.
[0106] Furthermore, epoxy(meth)acrylates, urethane(meth)acrylates
and polyester(meth)acrylates are also preferably used as the
photopolymerizable polyfunctional monomer.
[0107] Above all, esters of a polyhydric alcohol and (meth)acrylic
acid are preferable. Polyfunctional monomers containing three or
more (meth)acryloyl groups in one molecule thereof are more
preferable. Specific examples thereof include trimethylolpropane
tri(meth)acrylate, trimethylolethane tri(meth)acrylate,
1,2,4-cyclohexane tetra(meth)acrylate, pentaglycerol triacrylate,
pentaerythritol tetra(meth)acrylate, pentaerythritol
tri(meth)acrylate, (di)pentaertythritol triacrylate,
(di)pentaerythritol pentaacrylate, (di)pentaerythritol
tetra(meth)acrylate, (di)pentaerythritol hexa(meth)acrylate,
tripentaerythritol triacrylate and tripentaerythritol
hexatriacrylate.
[0108] Furthermore, for the purpose of controlling the refractive
index of each of the layers, a high refractive index monomer as a
photopolymerizable polyfunctional monomer can be used. In
particular, examples of a high refractive index monomer include
bis(4-methacryloylthiophenyl)sulfide, vinylnaphthalene, vinylphenyl
sulfide and 4-methacryloxyphenyl-4'-methoxyphenyl thioether.
[0109] Also, dendrimers described in, for example, JP-A-2005-76005
and JP-A-2005-36105 and norbornene ring-containing monomers
described in, for example, JP-2005-60425 can also be used.
[0110] In the case of using the foregoing curable compound, it is
preferred to use a photopolymerization initiator which is used for
a polymerization reaction of a photopolymerizable functional
monomer. As the photopolymerization initiator, a photo radical
polymerization initiator and a photo cationic polymerization
initiator are preferable, with the photo radical polymerization
initiator being especially preferable. The polymerization of the
monomer can be carried out in the presence of a photo radical
initiator upon irradiation with ionizing radiations.
(Photo Radical Polymerization Initiator)
[0111] Examples of the photo radical polymerization initiator
include acetophenones, benzoins, benzophenones, phosphine oxides,
ketals, anthraquinones, thioxanthones, azo compounds, peroxides
(for example, ones described in JP-A-2001-139663), 2,3-dialkyldione
compounds, disulfide compounds, fluoroamine compounds, aromatic
sulfoniums, onium salts, borate salts and active halogen
compounds.
[0112] Examples of the acetophenones include
2,2-diethoxyacetophenone, p-dimethylacetophenone, 1-hydroxydimethyl
phenyl ketone, 1-hydroxycyclohexyl phenyl ketone,
2-methyl-4-methylthio-2-morpholinopropiophenone and
2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)butanone.
[0113] Examples of the benzoins include benzoin benzenesulfonic
acid ester, benzoin toluenesulfonic acid ester, benzoin methyl
ether, benzoin ethyl ether and benzoin isopropyl ether.
[0114] Examples of the benzophenones include benzophenone,
2,4-dichlorobenzophenone, 4,4-dichlorobenzophenone and
p-chlorobenzophenone. Examples of the phosphine oxides include
2,4,6-trimethylbenzoyl diphenylphosphine oxide.
[0115] A variety of examples are described in Saishin UV Koko
Gijutsu (Latest UV Curing Technologies), page 159 (issuer: Kazuhiro
Takasusuki, publishing office: Technical Information Institute Co.,
Ltd., published in 1991); and Shigaisen Koka Shisutemu (Ultraviolet
Ray Curing Systems), pages 65 to 148 (written by Kiyoshi Kato and
published by Sogo Gijutsu Center) are useful in the invention.
[0116] Preferred examples of commercially available photo radical
polymerization initiators of a photo cleavage type include IRGACURE
Series (for example, 651, 184, 907, etc.) as trade names of Ciba
Japan K.K.
[0117] The photopolymerization initiator is preferably used in an
amount in the range of from 0.1 to 15 parts by mass, and more
preferably from 1 to 10 parts by mass based on 100 parts by mass of
the polyfunctional monomer.
(Photosensitizer)
[0118] In addition to the photopolymerization initiator, a
photosensitizer may be used. Specific examples of the
photosensitizer include n-butylamine, triethylamine, tri-n-butyl
phosphine, Michler's ketone and thioxanthone.
[0119] Also, in addition to the foregoing compounds, the
organosilane compounds described below can be preferably used as
the curable compound.
<(B) High Refractive Index Fine Particle Having a Refractive
Index of 1.55 or More>
[0120] The high refractive index fine particle (B) (hereinafter
also referred to as "high refractive index fine particle B") having
a refractive index of 1.55 or more, which is used in the invention,
is, for example, an inorganic fine particle having an average
particle size of 2 nm or more and not more than 100 nm, preferably
an inorganic fine particle having an average particle size of 5 nm
or more and not more than 80 nm, and further preferably an
inorganic fine particle having an average particle size of 10 nm or
more and not more than 60 nm.
[0121] When the average particle size is less than 2 nm, cohesion
is easily caused so that the separation is liable to become
difficult; whereas when it exceeds 100 nm, the haze is liable to
become large.
[0122] Examples of the high refractive index fine particle B
include the following inorganic fine particles. These inorganic
fine particles can be used singly or in admixture of two or more
kinds thereof. The average particle size of the high refractive
index fine particle B is measured by a Coulter counter.
[0123] The high refractive index fine particle B is preferably an
oxide particle of at least one element selected from the group
consisting of aluminum, zirconium, titanium, zinc, germanium,
indium, tin, antimony and cerium. In unevenly distributing such an
oxide inorganic fine particle in a lower part of the optical
functional layer, for the purposes of making the lower part have a
high refractive index and sufficiently reducing the reflectance of
the optical film of the invention, it is preferable that the oxide
inorganic fine particle has a high refractive index. The refractive
index is preferably from 1.60 to 3.00, more preferably from 1.80 to
2.90, and especially preferably from 1.90 to 2.80.
[0124] It is especially desired to use at least one oxide of a
metal selected from titanium and zirconium. Also, of the both,
zirconium which does not have a photo catalytic action is
preferable from the viewpoint of light fastness. However, it is
also preferable to use titanium having a controlled photo catalytic
action.
[0125] Also, it is desired to use a conductive inorganic fine
particle from the antistatic viewpoint; and it is desired to use at
least one oxide of a metal selected among indium, zinc, tin and
antimony.
[0126] The high refractive index fine particle B is also suitably
used as an inorganic fine particle for regulating the refractive
index in other respective layers to be used in the optical film of
the invention, for example, a hard coat layer or a middle
refractive index layer.
{Surface Treatment of High Refractive Index Fine Particle B}
[0127] Also, it is preferable that the foregoing high refractive
index fine particle B is surface-treated. A specific method for the
surface treatment is not particularly limited so far as dispersion
stabilization can be achieved in a dispersion to be added in the
coating composition, or affinity with and binding properties to a
resin component such as a binder can be enhanced. With respect to
the surface treatment, in addition to ones described in detail in
the "Dispersant and surface treating agent of high refractive index
fine particle B" item, an organosilane compound, a hydrolyzate of
the subject organosilane or a partial condensate of the hydrolyzate
of the subject organosilane is preferably used.
[Dispersant and Surface Treating Agent of High Refractive Index
Fine Particle B]
[0128] In order to achieve dispersion stabilization in a dispersion
or a coating solution or to enhance affinity with and binding
properties to the binder component, it is preferable that the high
refractive index fine particle B which is used in the invention is
subjected to a physical surface treatment such as a plasma
discharge treatment and a corona discharge treatment or a chemical
surface treatment with a surfactant, a coupling agent, etc.
[0129] The surface treatment can be carried out using a surface
treating agent made of an inorganic compound or an organic
compound. Examples of the inorganic compound which is used for the
surface treatment include cobalt-containing inorganic compounds
(for example, CoO.sub.2, Co.sub.2O.sub.3, CO.sub.3O.sub.4, etc.),
aluminum-containing inorganic compounds (for example,
Al.sub.2O.sub.3, Al(OH).sub.3, etc.), zirconium-containing
inorganic compounds (for example, ZrO.sub.2, Zr(OH).sub.4, etc.),
silicon-containing inorganic compounds (for example, SiO.sub.2,
etc.) and iron-containing inorganic compounds (for example,
Fe.sub.2O.sub.3, etc.).
[0130] Of these, cobalt-containing inorganic compounds,
aluminum-containing inorganic compounds and zirconium-containing
inorganic compounds are especially preferable; and
cobalt-containing inorganic compounds, Al(OH).sub.3 and
Zr(OH).sub.4 are the most preferable.
[0131] Examples of the organic compound which is used for the
surface treatment include polyols, alkanolamines, stearic acid,
silane coupling agents and titanate coupling agents. Of these,
silane coupling agents are the most preferable. It is especially
preferable that the surface treatment is carried out by using at
least one member of silane coupling agents (for example,
organosilane compounds) and partial hydrolyzates or condensates
thereof.
[0132] Examples of the titanate coupling agent include metal
alkoxides such as tetramethoxytitanium, tetraethoxytitanium and
tetraisopropoxytitanium; and PLENACT Series (for example, KR-TTS,
KR-46B, KR-55 and KR-41B, all of which are manufactured by
Ajinomoto Co., Inc., etc.).
[0133] As the organic compound which is used for the surface
treatment, polyols and alkanolamines and besides, anionic
group-containing organic compounds are preferable; and organic
compounds containing a carboxyl group, a sulfonic acid group or a
phosphoric acid group are especially preferable. Stearic acid,
lauric acid, oleic acid, linoleic acid, linolenic acid and so on
can be preferably used.
[0134] It is preferable that the organic compound which is used for
the surface treatment further contains a crosslinking or
polymerizable functional group. Examples of the crosslinking or
polymerizable functional group include ethylenically unsaturated
groups capable of undergoing an addition reaction or polymerization
reaction by a radical species (for example, a (meth)acryl group, an
allyl group, a stearyl group, a vinyloxy group, etc.), cationically
polymerizable groups (for example, an epoxy group, an oxatanyl
group, a vinyloxy group, etc.) and polycondensation reactive groups
(for example, a hydrolyzable silyl group, an N-methylol group,
etc.). Of these, groups having an ethylenically unsaturated group
are preferable.
[0135] A combination of two or more kinds of such surface treating
agents can be adopted. A combined use of an aluminum-containing
inorganic compound and a zirconium-containing inorganic compound is
especially preferable.
[0136] For the surface treatment, a coupling agent is preferably
used, too. Alkoxy metal compounds (for example, titanium coupling
agents or silane coupling agents) are preferably used as the
coupling agent. Above all, a silane coupling treatment is
especially effective. The silane coupling agent may be used as a
partial hydrolyzate or condensate thereof.
[0137] The foregoing coupling agent is used for undergoing a
surface treatment in advance prior to the preparation of a coating
solution as a surface treating agent of an inorganic fine particle.
It is preferred to incorporate the coupling agent in the subject
layer by further addition as an additive at the time of preparation
of the coating solution for the layer.
[0138] For the purpose of reducing a load of the surface treatment,
it is preferable that the high refractive index fine particle B is
dispersed in advance in a medium prior to the surface
treatment.
[0139] Specific examples of the surface treating agent and the
catalyst for the surface treatment which can be preferably used in
the invention include organosilane compounds and catalysts
described in, for example, WO 2004/017105.
[0140] A variety of dispersants as described below can be used for
dispersing the high refractive index fine particle B which is used
in the invention.
[0141] It is preferable that the dispersant further contains a
crosslinking or polymerizable functional group. Examples of the
crosslinking or polymerizable functional group include
ethylenically unsaturated groups capable of undergoing an addition
reaction or polymerization reaction by a radical species (for
example, a (meth)acryl group, an allyl group, a stearyl group, a
vinyloxy group, etc.), cationically polymerizable groups (for
example, an epoxy group, an oxatanyl group, a vinyloxy group, etc.)
and polycondensation reactive groups (for example, a hydrolyzable
silyl group or an N-methylol group). Of these, functional groups
having an ethylenically unsaturated group are preferable.
[0142] For dispersing the high refractive index fine particle B, in
particular, dispersing an inorganic particle composed of, as a
major component, TiO.sub.2, it is preferred to use a dispersant
containing an anionic group. It is more preferable that the
dispersant contains an anionic group and a crosslinking or
polymerizable functional group. It is especially preferable that
the subject crosslinking or polymerizable functional group is
contained in a side chain of the dispersant. As specific examples
of the crosslinking or polymerizable functional group, the
foregoing functional groups can be exemplified.
[0143] As the anionic group, groups having an acidic proton such as
a carboxyl group, a sulfonic acid group (sulfo), a phosphoric acid
group (phosphono) and a sulfonamide group, or salts thereof are
effective. Of these, a carboxyl group, a sulfonic acid group, a
phosphoric acid group, or a salt thereof is preferable, with a
carboxyl group or a phosphoric acid group being especially
preferable. With respect to the number of the anionic group per
molecule to be contained in the dispersant, plural kinds may be
contained in one molecule. The number of the anionic group per
molecule is preferably two or more, more preferably five or more,
and especially preferably ten or more in average. Also, plural
kinds of anionic groups to be contained in the dispersant may be
contained in one molecule.
[0144] In the dispersant having an anionic group in a side chain
thereof, the composition of an anionic group-containing repeating
unit is in the range of from 10.sup.-4 to 100% by mole, preferably
from 1 to 50% by mole, and especially preferably from 5 to 20% by
mole of the whole of the repeating units.
[0145] The number of the crosslinking or polymerizable functional
group per molecule to be contained in the dispersant is preferably
two or more, more preferably five or more, and especially
preferably ten or more in average. Also, plural kinds of
crosslinking or polymerizable functional groups to be contained in
the dispersant may be contained in one molecule.
[0146] In the preferred dispersant which is used in the invention,
as the repeating unit containing an ethylenically unsaturated group
in a side chain thereof, a repeating unit of a poly-1,2-butadiene
or poly-1,2-isoprene structure or a (meth)acrylic ester or amide,
to which is bound a specified residue (an R group in --COOR or
--CONHR), can be utilized. Examples of the foregoing specified
residue (R group) include
--(CH.sub.2).sub.n--CR.sub.21.dbd.CR.sub.22R.sub.23,
--(CH.sub.2O).sub.n--CH.sub.2CR.sub.21.dbd.CR.sub.22R.sub.23,
--(CH.sub.2CH.sub.2O).sub.n--CH.sub.2--CR.sub.21.dbd.CR.sub.22R.sub.23,
--(CH.sub.2).sub.n--NH--CO--O--CH.sub.2CR.sub.21.dbd.CR.sub.22R.sub.23,
--(CH.sub.2).sub.n--O--CO--CR.sub.21.dbd.CR.sub.22R.sub.23 and
--(CH.sub.2CH.sub.2O).sub.2--X (wherein R.sub.21 to R.sub.23 each
represents a hydrogen atom, a halogen atom, an alkyl group having
from 1 to 20 carbon atoms, an aryl group, an alkoxy group or an
aryloxy group; R.sub.21 and R.sub.22 or R.sub.23 may be taken
together to form a ring; n represents an integer of from 1 to 10;
and X represents a dicyclopentadienyl residue). Specific examples
of R of the ester residue include --CH.sub.2CH.dbd.CH.sub.2
(corresponding to a polymer of allyl(meth)acrylates described in
JP-A-64-17047), --CH.sub.2CH.sub.2O--CH.sub.2CHH.sub.2,
--CH.sub.2CH.sub.2OCOCH.dbd.CH.sub.2,
--CH.sub.2CH.sub.2OCOC(CH.sub.3)--CH.sub.2,
--CH.sub.2C(CH.sub.3).dbd.CH.sub.2,
--CH.sub.2CH.dbd.CH--C.sub.6H.sub.5,
--CH.sub.2CH.sub.2OCOCH.dbd.CH--C.sub.6H.sub.5,
--CH.sub.2CH.sub.2--NHCOO--CH.sub.2CH.dbd.CH.sub.2 and
--CH.sub.2CH.sub.2O--X (wherein X represents a dicyclopentadienyl
residue). Specific examples of R of the amide reside include
--CH.sub.2CH.dbd.CH.sub.2, --CH.sub.2CH.sub.2--Y (wherein Y
represents a 1-cyclohexenyl residue),
--CH.sub.2CH.sub.2--OCO--CH.dbd.CH.sub.2 and
--CH.sub.2CH.sub.2--OCO--C(CH.sub.3).dbd.CH.sub.2.
[0147] In the foregoing dispersant having an ethylenically
unsaturated group, a free radical (a polymerization initiation
radical or a growth radical in a polymerization process of a
polymerizable compound) is added to the unsaturated group, and
addition polymerization is caused directly between the molecules or
via a polymerization chain of the polymerizable compound, whereby
crosslinking is formed between the molecules to cause curing.
Alternatively, an atom in the molecule (for example, a hydrogen
atom on a carbon atom adjacent to the unsaturated binding group) is
withdrawn by the free radical to form polymer radicals which are
then bound to each other, whereby crosslinking is formed between
the molecules to cause curing.
[0148] Though the weight average molecular weight (Mw) of the
dispersant having an anionic group and a crosslinking or
polymerizable functional group and having the subject crosslinking
or polymerizable functional group in a side chain thereof is not
particularly limited, it is preferably 1,000 or more. The weight
average molecular weight (Mw) of the dispersant is more preferably
from 2,000 to 1,000,000, further preferably from 5,000 to 200,000,
and especially preferably from 10,000 to 100,000.
[0149] Though the crosslinking or polymerizable functional
group-containing unit may constitute all of the repeating units
other than the anionic group-containing repeating unit, it
preferably accounts for from 5 to 50% by mole, and especially
preferably from 5 to 30% by mole of the whole of the crosslinking
or repeating units.
[0150] The dispersant may be a copolymer with a suitable monomer
other than the monomer having a crosslinking or polymerizable
functional group and an anionic group. Though the copolymerization
component is not particularly limited, it is selected from various
viewpoints such as dispersion stability, compatibility with other
monomer component and strength of a formed film. Preferred example
thereof include methyl(meth)acrylate, n-butyl(meth)acrylate,
t-butyl(meth)acrylate, cyclohexyl(meth)acrylate and styrene.
[0151] Though the form of the dispersant is not particularly
limited, it is preferably a form of a block copolymer or a random
copolymer. It is especially preferably a form of a random copolymer
in view of cost and easiness for synthesis.
[0152] The use amount of the dispersant relative to the high
refractive index fine particle B is preferably in the range of from
1 to 50% by mass, more preferably in the range of from 5 to 30% by
mass, and most preferably in the range of from 5 to 20% by mass.
Furthermore, two or more kinds of dispersants may be used in
combination. Details of the dispersant which is preferably used are
described in JP-A-2007-293313.
[Dispersion of High Refractive Index Fine Particle B]
[0153] The high refractive index fine particle B can be dispersed
using a dispersion machine. Examples of the dispersion machine
include a sand grinder mill (for example, a pin-provided bead
mill), a high-speed impeller mill, a pebble mill, a roller mill, an
attritor and a colloid mill. Of these, a sand grinder mill and a
high-speed impeller mill are especially preferable. Furthermore, a
preliminary dispersion treatment may be carried out. Examples of a
dispersion machine which is used for the preliminary dispersion
treatment include a ball mill, a three-roll mill, a kneader and an
extruder.
[0154] It is preferable that the high refractive index fine
particle B is atomized in the dispersion medium as far as possible.
Its weight average particle preferably follows the foregoing
particle size.
{Surface Free Energy of High Refractive Index Fine Particle B}
[0155] It is preferable from the standpoint of advantageously
forming a layer separation structure that the surface free energy
of the high refractive index fine particle B is higher than the
surface free energy of the fluorine-containing compound and higher
than that of the low refractive index fine particle. The surface
free energy of the high refractive index fine particle B is
preferably 55 mN/m or more, more preferably 55 mN/m or more and not
more than 70 mN/m, and especially preferably 55 mN/m or more and
not more than 65 mN/m. By making the surface free energy of the
high refractive index fine particle B fall within the foregoing
range, the layer separation structure is easily formed. On the
other hand, when the surface free energy of the high refractive
index fine particle B is too high, a lowering of reflectance,
unevenness, etc. may be possibly generated. The surface free energy
is preferably controlled so as to fall within the foregoing range
from the viewpoints of strength and coating properties.
[0156] The surface free energy of the high refractive index fine
particle B can be calculated using a contact angle of the high
refractive index fine particle B against water and methylene
iodide, which is obtained by, after stationary sedimentation or
centrifugation of a coating composition, repeating rinsing with a
solvent to remove components other than the high refractive index
fine particle B, casting it on a rinsed glass plate, drying the
solvent and forming it into a thin film. The surface free energy of
other components such as resin components can be similarly
calculated.
[0157] A blending proportion of the high refractive index fine
particle B in the optical functional layer is preferably in the
range of from 30% by mass to 50% by mass, and more preferably in
the range of from 30% by mass to 40% by mass relative to the whole
of solids of the optical functional layer.
<(A) Low Refractive Index Fine Particle Having a Refractive
Index of not More than 1.45>
[0158] The low refractive index fine particle (A) (hereinafter also
referred to as "low refractive index fine particle A") having a
refractive index of not more than 1.45, which is used in the
invention, is, for example, an inorganic fine particle having an
average particle size of 10 nm or more and not more than 100 nm,
preferably an inorganic fine particle having an average particle
size of 15 nm or more and not more than 80 nm, and further
preferably an inorganic fine particle having an average particle
size of 20 nm or more and not more than 60 nm. The refractive index
of the low refractive index fine particle A is not more than 1.45,
preferably from 1.17 to 1.45, more preferably from 1.17 to 1.40,
further preferably from 1.17 to 1.35, and most preferably from 1.17
to 1.32. In order that the low refractive index fine particle A may
be maldistributed in an upper part of the optical functional layer,
thereby contributing to an enhancement of the scratch resistance
and a reduction of the refractive index, it is desirable that the
low refractive index fine particle A has a low refractive
index.
[0159] Examples of the low refractive index fine particle A include
the following inorganic fine particles. These inorganic fine
particles can be used singly or in admixture of two or more kinds
thereof.
[0160] Specific examples of the low refractive index fine particle
A include fine particles of magnesium fluoride and silicon oxide
(silica). In view of refractive index, dispersion stability and
cost, a silica fine particle is especially preferable.
[0161] When the particle size of the low refractive index fine
particle A is too small, an effect for improving the scratch
resistance becomes low, whereas when it is too large, fine
irregularities are formed on the surface of the optical functional
layer and the appearance such as deep black and integrated
reflectance are deteriorated. Thus, it is preferred to control the
particle size of the low refractive index fine particle A to the
foregoing range. The low refractive index fine particle A may be
either crystalline or amorphous; it may be a monodispersed
particle; and so far as a prescribed particle size is met, it may
be a cohered particle. Though the shape of the low refractive index
fine particle A is most preferably spherical, even when it is
amorphous, there is no problem.
[0162] Here, the average particle size of the low refractive index
fine particle A is measured by a Coulter counter.
[0163] It is further preferable that the low refractive index fine
particle A has a hollow structure. In the case of an inorganic fine
particle of a hollow structure, the refractive index does not
express a refractive index of only the inorganic material as an
outer shell but expresses an average value of the whole of the
particle. At that time, when a radius of a void within the particle
is defined as "a", and a radius of the outer shell of the particle
is defined as "b", a porosity x which is expressed by the following
numerical expression (II):
x=(4.pi.a.sup.3/3)/(4.pi.b.sup.3/3).times.100 Expression (II)
is preferably from 10 to 60%, more preferably from 20 to 60%, and
most preferably from 30 to 60%.
[0164] When it is intended to make the hollow low refractive index
fine particle A so as to have a lower refractive index and a larger
porosity, the thickness of only the outer shell becomes thin so
that the strength as the particle is weakened. Accordingly, a
particle having a low refractive index of less than 1.17 is not
preferable from the viewpoint of scratch resistance. The refractive
index of the inorganic fine particle can be measured by an Abbe's
refractometer (manufactured by Atago Co., Ltd.).
[0165] The amount of the low refractive index fine particle A is
preferably in the range of from 5% by mass to 15% by mass, more
preferably from 8% by mass to 15% by mass, and especially
preferably from 10% by mass to 15% by mass relative to the whole of
solids of the optical functional layer. When the amount of the low
refractive index fine particle A is too high, the low refractive
index fine particle A is cohered and maldistributed in a lower part
in the high refractive index fine particle layer, whereby the
effect for reducing the reflectance is lowered. Also, when the
amount of the low refractive index fine particle A is too low, the
number of particles which are maldistributed on the surface
decreases, whereby not only the effect for reducing the reflectance
is lowered, but the physical strength of the optical functional
layer is weakened.
[0166] The low refractive index fine particle A is especially
preferably a silica fine particle or a hollow silica fine
particle.
{Surface Treatment of Low Refractive Index Fine Particle A}
[0167] In order to achieve dispersion stabilization in a dispersion
or a coating solution or to enhance affinity with and binding
properties to the binder component, the low refractive index fine
particle A may be subjected to a physical surface treatment such as
a plasma discharge treatment and a corona discharge treatment or a
chemical surface treatment with a surfactant, a coupling agent,
etc. Above all, the use of a coupling agent is especially
preferable. Alkoxy metal compounds (for example, titanium coupling
agents or silane coupling agents) are preferably used as the
coupling agent. Above all, a silane coupling treatment is
especially effective.
[0168] Furthermore, it is desirable that the silane coupling agent
does not contain a fluorine atom. When the low refractive index
fine particle A is surface-treated with a fluorine atom-free silane
coupling agent, the compatibility of the low refractive index fine
particle A with (C) the fluorine compound decreases, and the low
refractive index fine particle A is not completely taken into the
fluorine compound, whereby the separation proceeds, and it is
easily maldistributed on the surface. Accordingly, such is
advantageous in forming the layer separation structure of the
invention. When the silane coupling agent contains a fluorine atom,
there is a possibility that the low refractive index fine particle
A is not arranged in a line on the surface but distributed even in
the inside of the optical functional layer, whereby the reflectance
increases, and the scratch resistance is deteriorated.
[0169] It is preferable that the foregoing coupling agent is used
for undergoing a surface treatment in advance prior to the
preparation of a coating solution as a surface treating agent of
the low refractive index fine particle A. It is preferred to
incorporate the coupling agent in the subject layer by further
addition as an additive at the time of preparation of the coating
solution for the layer.
[0170] For the purpose of reducing a load of the surface treatment,
it is preferable that the low refractive index fine particle A is
dispersed in advance in a medium prior to the surface
treatment.
<Silane Coupling Agent>
[0171] It is preferable from the standpoints of scratch resistance
and surface free energy that at least one member selected among an
organosilane compound, a hydrolyzate of the subject organosilane
compound and a partial condensate of the hydrolyzate of the subject
organosilane compound (the resulting reaction solution will be
hereinafter sometimes referred to as "sol component") is
incorporated as the surface treating agent of the low refractive
index fine particle A.
[0172] Such a component functions as a binder such that after
coating, the foregoing coating composition is condensed in drying
and heating steps to form a cured material. Also, in the invention,
since the foregoing fluorine-containing polymer is preferably
incorporated as the fluorine-containing compound, a binder having a
three-dimensional structure is formed upon irradiation with active
rays.
[0173] The foregoing organosilane compound is preferably one
represented by the following formula (1).
(R.sup.1).sub.m--Si(X).sub.4-m Formula (1)
[0174] In the foregoing formula (1), R.sup.1 represents a
substituted or unsubstituted alkyl group or a substituted or
unsubstituted aryl group. Examples of the alkyl group include
methyl, ethyl, propyl, isopropyl, hexyl, decyl and hexadecyl. The
alkyl group preferably has from 1 to 30 carbon atoms, more
preferably from 1 to 16 carbon atoms, and especially preferably
from 1 to 6 carbon atoms. Examples of the aryl group include phenyl
and naphthyl, with a phenyl group being preferable.
[0175] X represents a hydroxyl group or a hydrolyzable group.
Examples of the hydrolyzable group include an alkoxy group
(preferably an alkoxy group having from 1 to 6 carbon atoms, for
example, a methoxy group and an ethoxy group), a halogen atom (for
example, Cl, Br, I, etc.) and R.sub.2COO (wherein R.sub.2 is
preferably a hydrogen atom or an alkyl group having from 1 to 5
carbon atoms; and examples thereof include CH.sub.3COO and
C.sub.2H.sub.5COO). Of these, an alkoxy group is preferable; and a
methoxy group and an ethoxy group are especially preferable. [0176]
m represents an integer of from 1 to 3, preferably 1 or 2, and
especially preferably 1.
[0177] When plural R.sub.1s or Xs are present, the plural R.sub.1s
or Xs may be the same or different.
[0178] The substituent which is contained in R.sub.1 is not
particularly limited, and examples thereof include a halogen atom
(for example, fluorine, chlorine, bromine, etc.), a hydroxyl group,
a mercapto group, a carboxyl group, an epoxy group, an alkyl group
(for example, methyl, ethyl, isopropyl, propyl, t-butyl, etc.), an
aryl group (for example, phenyl, naphthyl, etc.), an aromatic
heterocyclic group (for example, furyl, pyrazolyl, pyridyl, etc.),
an alkoxy group (for example, methoxy, ethoxy, isopropoxy,
hexyloxy, etc.), an aryloxy group (for example, phenoxy, etc.), an
alkylthio group (for example, methylthio, ethylthio, etc.), an
arylthio group (for example, phenylthio, etc.), an alkenyl group
(for example, vinyl, 1-propenyl, etc.), an acyloxy group (for
example, acetoxy, acryloyloxy, methacryloyloxy, etc.), an
alkoxycarbonyl group (for example, methoxycarbonyl, ethoxycarbonyl,
etc.), an aryloxycarbonyl group (for example, phenoxycarbonyl,
etc.), a carbamoyl group (for example, carbamoyl,
N-methylcarbamoyl, N,N-dimethylcarbamoyl,
N-methyl-N-octylcarbamoyl, etc.) and an acylamino group (for
example, acetylamino, benzoylamino, acrylamino, methacrylamino,
etc.). Such a substituent may be further substituted.
[0179] In the case where plural R.sub.1s are present, it is
preferable that at least one of them is a substituted alkyl group
or a substituted aryl group. Among the organosilane compounds
represented by the foregoing formula (1), an organosilane compound
having a vinyl polymerizable substituent represented by the
following formula (2) is preferable.
##STR00001##
[0180] In the foregoing formula (2), R.sup.10 represents a hydrogen
atom, a methyl group, a methoxy group, an alkoxycarbonyl group, a
cyano group, a fluorine atom or a chlorine atom. Examples of the
alkoxycarbonyl group include a methoxycarbonyl group and an
ethoxycarbonyl group. Above all, a hydrogen atom, a methyl group, a
methoxy group, a methoxycarbonyl group, a cyano group, a fluorine
atom and a chlorine atom are preferable; a hydrogen atom, a methyl
group, a methoxycarbonyl group, a fluorine atom and a chlorine atom
are more preferable; and a hydrogen atom and a methyl group are
especially preferable.
[0181] Y represents a single bond, *--COO--**, *--CONH--** or
*--O--**. Of these, a single bond, *--COO--** and *--CONH--** are
preferable; a single bond and *--COO--** are more preferable; and
*--COO--** is especially preferable. Here, * represents the binding
position to .dbd.C(R.sup.1); and ** represents the binding position
to L.
[0182] L represents a divalent connecting chain. Specific examples
thereof include a substituted or unsubstituted alkylene group, a
substituted or unsubstituted arylene group, a substituted or
unsubstituted alkylene group having a connecting group (for
example, ethers, esters, amides, etc.) therein and a substituted or
unsubstituted arylene group containing a connecting group therein.
Of these, a substituted or unsubstituted alkylene group, a
substituted or unsubstituted arylene group and an alkylene group
having a connecting group therein are preferable; an unsubstituted
alkylene group, an unsubstituted arylene group and an alkylene
group having an ether or ester connecting group therein are more
preferable; and an unsubstituted alkylene group and an alkylene
group having an ether or ester connecting group therein are
especially preferable. Examples of the substituent include a
halogen, a hydroxyl group, a mercapto group, a carboxyl group, an
epoxy group, an alkyl group and an aryl group. Such a substituent
may be further substituted.
[0183] n represents 0 or 1. When plural Xs are present, the plural
Xs may be the same or different. n is preferably 0.
[0184] R.sup.1 is synonymous with R.sup.1 in the formula (1) and is
preferably a substituted or unsubstituted alkyl group or an
unsubstituted aryl group, and more preferably an unsubstituted
alkyl group or an unsubstituted aryl group.
[0185] X is synonymous with X in the formula (1). Above all, a
halogen atom, a hydroxyl group and an unsubstituted alkoxy group
are preferable; a chlorine atom, a hydroxyl group and an alkoxy
group having from 1 to 6 carbon atoms are more preferable; a
hydroxyl group and an alkoxy group having from 1 to 3 carbon atoms
are further preferable; and a methoxy group is especially
preferable.
[0186] The compound of the foregoing formula (1) or formula (2) may
be used in combination of two or more kinds thereof. Specific
examples of the compound represented by the formula (1) or formula
(2) will be given below, but it should not be construed that the
invention is limited thereto.
##STR00002## ##STR00003## ##STR00004## ##STR00005##
[0187] Of the compounds represented by the foregoing M-1 to M-55,
M-1, M-2 and M-49 are preferable. In the invention, though the use
amount of the silane coupling agent represented by the formula (1)
is not particularly limited, it is preferably from 1% by mass to
300% by mass, more preferably from 3% by mass to 100% by mass, and
most preferably from 5% by mass to 50% by mass per the low
refractive index fine particle. By regulating the addition amount
of the silane coupling agent, the treatment state on the surface of
the low refractive index fine particle can be regulated, thereby
enabling one to regulate the condition suitable for the formation
of the layer separation structure of the invention.
[0188] In general, a hydrolyzate of the foregoing organosilane
compound and/or a partial condensate thereof is produced by
treating the foregoing organosilane compound in the presence of a
catalyst. Examples of the catalyst include inorganic acids such as
hydrochloric acid, sulfuric acid and nitric acid; organic acids
such as oxalic acid, acetic acid, formic acid, methanesulfonic acid
and toluenesulfonic acid; inorganic bases such as sodium hydroxide,
potassium hydroxide and ammonia; organic bases such as
triethylamine and pyridine; metal alkoxides such as
triisopropoxyaluminum and tetrabutoxyzirconium; and metal chelate
compounds containing a metal (for example, Zr, Ti, Al, etc.) as a
central metal. In the invention, it is preferred to use a metal
chelate compound or an acid catalyst such as inorganic acids and
organic acids. Hydrochloric acid and sulfuric acid are preferable
as the inorganic acid; and ones having an acid dissociation
constant (pKa value (at 25.degree. C.)) in water of not more than
4.5 are preferable as the organic acid. Hydrochloric acid, sulfuric
acid and an organic acid having an acid dissociation constant in
water of not more than 3.0 are more preferable; hydrochloric acid,
sulfuric acid and an organic acid having an acid dissociation
constant in water of not more than 2.5 are further preferable; and
an organic acid having an acid dissociation constant in water of
not more than 2.5 is especially preferable. Concretely,
methanesulfonic acid, oxalic acid, phthalic acid and malonic acid
are preferable, with oxalic acid being especially preferable.
[0189] As the metal chelate compound, ones containing, as a central
metal, a metal selected from Zr, Ti and Al, in which an alcohol
represented by the formula, R.sup.3OH (wherein R.sup.3 represents
an alkyl group having from 1 to 10 carbon atoms) and a compound
represented by the formula, R.sup.4COCH.sub.2COR.sup.5 (wherein
R.sup.4 represents an alkyl group having from 1 to 10 carbon atoms;
and R.sup.5 represents an alkyl group having from 1 to 10 carbon
atoms or an alkoxy group having from 1 to 10 carbon atoms) function
as ligands, can be suitably used without particular limitations.
Two or more kinds of metal chelate compounds may be used in
combination within this scope. The metal chelate compound which is
used in the invention is preferably selected from the group of
compounds represented by the formulae,
Zr(OR.sup.3).sub.p1(R.sup.4COCHCOR.sup.5).sub.p2,
Ti(OR.sup.3).sub.q1(R.sup.4COCHCOR.sup.5).sub.q2 and
Al(OR.sup.3).sub.r1(R.sup.4COCHCOR.sup.5).sub.r2 and acts to
accelerate a condensation reaction of a hydrolyzate of the
foregoing organosilane compound and/or a partial condensate
thereof.
[0190] In the foregoing metal chelate compounds, R.sup.3 and
R.sup.4 may be the same or different and each represents an alkyl
group having from 1 to 10 carbon atoms. Specific examples of the
alkyl group include an ethyl group, an n-propyl group, an isopropyl
group, an n-butyl group, a sec-butyl group, a t-butyl group and an
n-pentyl group. Also, R.sup.5 represents an alkyl group having from
1 to 10 carbon atoms the same as in the foregoing or an alkoxy
group having from 1 to 10 carbon atoms. Examples of the alkoxy
group include a methoxy group, an ethoxy group, an n-propoxy group,
an isopropoxy group, an n-butoxy group, a sec-butoxy group and a
t-butoxy group. Also, in the foregoing metal chelate compounds, p1,
p2, q1, q2, r1 and r2 each represents an integer which is
determined such that the relations: (p1+p2)=4, (q1+q2)=4 and
(r1+r2)=3 are satisfied.
[0191] Specific examples of such a metal chelate compound include
zirconium chelate compounds such as zirconium
tri-n-butoxyethylacetoacetate, zirconium
di-n-butoxybis(ethylacetoacetate), zirconium
n-butoxytris(ethylacetoacetate), zirconium
tetrakis(n-propylaetoacetate), zirconnium
tetrakis(acetylacetoacetate) and zirconium
tetrakis(ethylacetoacetate); titanium chelate compounds such as
titanium diisopropoxy.bis(ethylacetoacetate), titanium
diisopropoxy.bis(acetylacetate), and titanium
diisopropoxy.bis(acetylcetone); and aluminum chelate compounds such
as aluminum diisopropoxyethylacetoacetate, aluminum
diisopropoxyacetylacetate, aluminum
isopropoxybis(ethylacetoacetate), aluminum
isopropoxybis(acetylacetonate), aluminum tris(ethylacetoacetate),
aluminum tris(acetylacetonate) and aluminum
monoacetylacetonato.bis(ethylacetoacetate).
[0192] Of the foregoing specific examples of the metal chelate
compound, zirconium tri-n-butoxyethylacetoacetate, titanium
diisopropoxybis(acetylacetonate), aluminum
diisopropoxyethylacetoacetate and aluminum tris(ethylacetoacetate)
are preferable. Such a metal chelate compound can be used singly or
in admixture of two or more kinds thereof. A partial hydrolyzate of
such a metal chelate compound can also be used.
[0193] In the invention, it is preferable that a .beta.-diketone
compound and/or a .beta.-ketoester compound is further added. This
is further described below.
[0194] The compound which is used in the invention is a
.beta.-diketone compound and/or a .beta.-ketoester compound
represented by the formula, R.sup.4COCH.sub.2COR.sup.5 and acts as
a stability enhancing agent of the surface treating agent which is
used in the invention. Here, R.sup.4 represents an alkyl group
having from 1 to 10 carbon atoms; and R.sup.5 represents an alkyl
group having from 1 to 10 carbon atoms or an alkoxy group having
from 1 to 10 carbon atoms. That is, it may be considered that when
this compound coordinates with the metal atom in the metal chelate
compound (for example, zirconium, titanium and/or aluminum
compounds), it inhibits an action to accelerate a condensation
reaction of a hydrolyzate of the organosilane compound and/or a
partial condensate thereof by such a metal chelate compound,
thereby acting to enhance the storage stability of the resulting
surface treating agent. R.sup.4 and R.sup.5 which constitute the
.beta.-diketone compound and/or .beta.-ketoester compound are
synonymous with R.sup.4 and R.sup.5 which constitute the foregoing
metal chelate compound.
[0195] Specific examples of this .beta.-diketone compound and/or
.beta.-ketoester compound include acetylacetone, methyl
acetoacetate, ethyl acetoacetate, n-propyl acetoacetate, isopropyl
acetoacetate, n-butyl acetoacetate, sec-butyl acetoacetate, t-butyl
acetoacetate, 2,3-hexane-dione, 2,4-heptane-dione,
3,5-heptane-dione, 2,4-octane-dione, 2,4-nonane-dione and
5-methylhexane-dione. Of these, ethyl acetoacetate and
acetylacetone are preferable; and acetylacetone is especially
preferable. Such a .beta.-diketone compound and/or .beta.-ketoester
compound can be used singly or in admixture of two or more kinds
thereof. In the invention, the .beta.-diketone compound and/or
.beta.-ketoester compound is preferably used in an amount of 2
moles or more, and more preferably from 3 to 20 moles per mole of
the metal chelate compound. Satisfactory storage stability is
obtained within the foregoing range.
{Surface Free Energy of Low Refractive Index Fine Particle A}
[0196] It is preferable from the standpoint of maldistribution of
the low refractive index fine particle A in an upper part of the
layer that the surface free energy of the low refractive index fine
particle A is lower than the surface free energy of the high
refractive index fine particle B and that the surface free energy
of the low refractive index fine particle A is from 35 to 55 mN/m
or more. The surface free energy of the low refractive index fine
particle A is more preferably from 35 to 50 mN/m, and most
preferably from 35 to 45 mN/m. By making the surface free energy of
the low refractive index fine particle A fall within the foregoing
range, when the coating composition is coated, the both particles
are easily separated to form a layer. The surface free energy can
be measured in the same method as in the surface free energy of the
foregoing high refractive index fine particle B.
<Organic Solvent>
[0197] As an organic solvent which is used for the coating
composition in the invention, a variety of solvents which are
selected from the viewpoints that each component can be dissolved
or dispersed therein; that uniform surface properties are liable to
be obtained in a coating step and a drying step; that liquid
preservability can be ensured; and that they have a proper
saturated vapor pressure can be used.
[0198] The solvent may be used singly or in admixture of two or
more kinds thereof. In particular, it is preferable from the
viewpoint of a drying load that a solvent having a boiling point of
not higher than 100.degree. C. at room temperature under
atmospheric pressure is used as a major component, whereas a small
amount of a solvent having a boiling point of 100.degree. C. or
higher is contained for the purpose of adjusting the drying speed
(the amount of the solvent having a boiling point of 100.degree. C.
or higher is preferably from 1 to 50 parts by mass, more preferably
from 2 to 40 parts by mass, and especially preferably from 3 to 30
parts by mass based on 100 parts by mass of the solvent having a
boiling point of 100.degree. C. or higher). By using at least two
kinds of organic solvents having a different boiling point from
each other, the high refractive index fine particle B is easily
maldistributed in a lower part.
[0199] Examples of the solvent having a boiling point of not higher
than 100.degree. C. include hydrocarbons such as hexane (boiling
point: 68.7.degree. C.), heptane (boiling point: 98.4.degree. C.),
cyclohexane (boiling point: 80.7.degree. C.) and benzene (boiling
point: 80.1.degree. C.); halogenated hydrocarbons such as
dichloromethane (boiling point: 39.8.degree. C.), chloroform
(boiling point: 61.2.degree. C.), carbon tetrachloride (boiling
point: 76.8.degree. C.), 1,2-dichloroethane (boiling point:
83.5.degree. C.) and trichloroethylene (boiling point: 87.2.degree.
C.); ethers such as diethyl ether (boiling point: 34.6.degree. C.),
diisopropyl ether (boiling point: 68.5.degree. C.), dipropyl ether
(boiling point: 90.5.degree. C.) and tetrahydrofuran (boiling
point: 66.degree. C.); esters such as ethyl formate (boiling point:
54.2.degree. C.), methyl acetate (boiling point: 57.8.degree. C.),
ethyl acetate (boiling point: 77.1.degree. C.) and isopropyl
acetate (boiling point: 89.degree. C.); ketones such as acetone
(boiling point: 56.1.degree. C.) and 2-butanone (the same as methyl
ethyl ketone, boiling point: 79.6.degree. C.); alcohols such as
methanol (boiling point: 64.5.degree. C.), ethanol (boiling point:
78.3.degree. C.), 2-propnaol (boiling point: 82.4.degree. C.) and
1-propanol (boiling point: 97.2.degree. C.); cyano compounds such
as acetonitrile (boiling point: 81.6.degree. C.) and propionitrile
(boiling point: 97.4.degree. C.); and carbon disulfide (boiling
point: 46.2.degree. C.). Of these, ketones and esters are
preferable; and ketones are especially preferable. Among the
ketones, 2-butanol is especially preferable.
[0200] Examples of the solvent having a boiling point of
100.degree. C. or higher include octane (boiling point:
125.7.degree. C.), toluene (boiling point: 110.6.degree. C.),
xylene (boiling point: 138.degree. C.), tetrachloroethylene
(boiling point: 121.2.degree. C.), chlorobenzene (boiling point:
131.7.degree. C.), dioxane (boiling point: 101.3.degree. C.),
dibutyl ether (boiling point: 142.4.degree. C.), isobutyl acetate
(boiling point: 118.degree. C.), cyclohexanone (boiling point:
155.7.degree. C.), 2-methyl-4-pentanone (the same as MIBK, boiling
point: 115.9.degree. C.), 1-butanol (boiling point: 117.7.degree.
C.), N,N-dimethylformamide (boiling point: 153.degree. C.),
N,N-dimethylacetamide (boiling point: 166.degree. C.) and dimethyl
sulfoxide (boiling point: 189.degree. C.). Of these, cyclohexanone
and 2-methyl-4-pentanone are preferable.
[0201] As another preferred embodiment of using two or more kinds
of organic solvents, the use of two kinds of solvents in which a
difference in the boiling point is larger than a specified value is
exemplified. The difference in the boiling point between the two
kinds of solvents is preferably 25.degree. C. or more, especially
preferably 35.degree. C. or more, and further preferably 50.degree.
C. or more. When the difference in the boiling point is large, the
high refractive index fine particle (B) is easily maldistributed in
a lower part.
[0202] As to the blending proportion of the organic solvent, the
organic solvent is added such that the solids concentration is
preferably from 2 to 30% by mass, more preferably from 3 to 20% by
mass, and especially preferably from 5 to 15% by mass. When the
solids concentration is too low, there is a concern that it takes a
time to conduct drying, or unevenness in thickness to be caused due
to drying likely occurs. On the other hand, when the solids
concentration is too high, there is a concern that maldistribution
of the particle does not sufficiently occur, or the coating amount
becomes small, whereby coating unevenness likely occurs.
[0203] In the coating composition of the invention, in addition to
the foregoing respective components, other additives can be added
and used. As other additives which can be used in the invention,
the following additives are exemplified.
<Leveling Agent>
[0204] For the purpose of preventing unevenness, various leveling
agents can be used. Concretely, a fluorine based leveling agent or
a silicone based leveling agent is preferable as the leveling
agent. In particular, a fluorine based leveling agent is more
preferable because an ability to prevent unevenness is high.
[0205] Also, as the leveling agent, an oligomer or a polymer is
more preferable than a low molecular weight compound.
[0206] As such a monomer, ones described in Polymer Handbook, 2nd
Ed., J. Brandrup, Wiley Interscience (1975), Chapter 2, pages 1 to
483 can be used.
[0207] Examples thereof include compounds having one addition
polymerizable unsaturated bond selected among acrylic acid,
methacrylic acid, acrylic esters, methacrylic esters, acrylamides,
methacrylamides, allyl compounds, vinyl ethers vinyl esters and the
like.
[0208] Examples of the silicone based leveling agent include
polydimethylsiloxanes in which a side chain thereof or a terminal
end of a principal chain thereof is modified with various
substituents such as oligomers of ethylene glycol, propylene
glycol, etc., and specific examples thereof include KF-96 and
X-22-945, all of which are manufactured by Shin-Etsu Chemical Co.,
Ltd. Besides, nonionic surfactants in which a hydrophobic group
thereof is constituted of a dimethyl polysiloxane and a hydrophilic
group thereof is constituted of a polyoxyalkylene can also be
preferably used. The addition amount of the fluorine based leveling
agent is preferably from 0.001% by mass to 1.0% by mass, and more
preferably from 0.01% by mass to 0.2% by mass relative to the
coating solution.
[0209] A thickener can be used for the purpose of regulating the
viscosity of the coating composition. The "thickener" as referred
to herein means a substance capable of increasing the viscosity of
the solution upon addition of the same.
[0210] Details of the leveling agent and the thickener are
described in JP-A-2007-293313.
[Underlying Layer]
[0211] As an underlying layer of the optical functional layer which
is formed from the foregoing coating composition, a hard coat layer
is preferable. It is preferable that the hard coat layer is formed
from a composition containing at least one of the foregoing curable
compound and high refractive index fine particle. By incorporating
at least one of these two components, adhesion between the layers
can be enhanced, the scratch resistance can be enhanced, or the
high refractive index fine particle B can be easily maldistributed
in a lower part within the optical functional layer which is formed
from the foregoing coating composition. Also, in order to impart an
antiglare function, the hard coat layer may have an irregular
structure on the surface thereof.
[0212] As described above, the underlying layer may have other
functional layer.
[Optical Film]
[0213] The optical film of the invention is an optical film
comprising a transparent support having thereon an optical
functional layer as an outermost surface, wherein the optical
functional layer has a thickness of 50 nm or more and not more than
250 nm; the optical functional layer contains (A) a low refractive
index fine particle having a refractive index of not more than
1.45, (B) a high refractive index fine particle having a refractive
index of 1.55 or more and (C) a fluorine-containing compound; the
low refractive index fine particle is arranged substantially in a
line on the surface of the optical functional layer on the opposite
side of the transparent support; and the high refractive index fine
particle is maldistributed in a lower part of the optical
functional layer on the side of the transparent support.
[0214] The optical film of the invention is hereunder described in
more detail.
[0215] In the optical functional layer in the invention, it is
preferable that a ratio of an average particle packing factor
P.sub.Lu, in the 30% thickness in an upper part of the optical
functional layer on the opposite side of the transparent support to
an average particle packing factor P.sub.Lt of the low refractive
index fine particle A in the whole layer of the optical functional
layer [(P.sub.Lu/P.sub.Lt).times.100] is 200% or more.
[0216] Also, it is preferable that a ratio of an average particle
packing factor P.sub.Hd in the 50% thickness in a lower part of the
optical functional layer on the side of the transparent support to
an average particle packing factor P.sub.Ht of the high refractive
index fine particle in the whole layer of the optical functional
layer [(P.sub.Hd/P.sub.Ht).times.100] is 120% or more.
[0217] The arrangement of the low refractive index fine particle
and the state of maldistribution of the high refractive index fine
particle can be confirmed through observation of a cross section of
the optical film by a transmission electron microscope (TEM). Also,
the distribution of the low refractive index fine particle can be
determined by a ratio of an average particle packing factor
P.sub.Lu in the 30% thickness in an upper part of the optical
functional layer on the opposite side of the transparent support to
an average particle packing factor P.sub.Lt of the low refractive
index fine particle in the whole layer of the optical functional
layer [(P.sub.Lu/P.sub.Lt).times.100]; and the distribution of the
high refractive index fine particle can be determined by a ratio of
an average particle packing factor P.sub.Hd in the 50% thickness in
a lower part of the optical functional layer on the side of the
transparent support to an average particle packing factor P.sub.Ht
of the high refractive index fine particle in the whole layer of
the optical functional layer [(P.sub.Hd/P.sub.Ht).times.100]. In
the invention, P.sub.Lt, P.sub.Lu, P.sub.Ht and P.sub.Hd were
determined according to the following methods.
[0218] The optical film was sliced in a thickness of 50 nm, and its
cross section was subjected to five-visual field photographing by a
transmission electron microscope with a magnification of 150,000.
The thickness of each of a portion where the high refractive index
fine particle exists and a portion where the high refractive index
fine particle does not exist is measured in 100 points over a width
having a length of 50 times relative to the thickness of the
optical functional layer, and an average value thereof is defined
as a thickness of each of the high refractive index layer and the
low refractive index layer.
[0219] Also, the number of the low refractive index fine particle
in the width of the same length was counted, from which was then
calculated P.sub.u as the particle number per unit area in the
optical functional layer on the cross-sectional photograph. Also,
the number of the low refractive index fine particle in the 30%
thickness in an upper part of the optical functional layer was
counted, from which was then calculated P.sub.Lu in the same
manner. In the same method, the number of the high refractive index
fine particle was counted, from which was then calculated P.sub.Ht;
and the particle number in the 50% thickness in a lower part of the
optical functional layer was counted, from which was then
calculated P.sub.Hd.
[0220] For example, in the case where the low refractive index fine
particle was partially observed in the 30% thickness in an upper
part of the optical functional layer, the particle number was
calculated by multiplying a proportion of an area of the particle
contained in the subject region on the cross-sectional photograph;
and in the case where the particle was observed superimposed, the
superimposed portion was also counted as one. In that case, the
in-layer distribution of the particle does not have directivity in
a layer plane direction, and the average particle packing factor
can be determined on the basis of the counted number of particles
on a specified cross section selected as the slice.
[0221] In the invention, the [(P.sub.Lu/P.sub.Lt).times.100] is
desirably 200% or more. When the [(P.sub.Lu/P.sub.Lt).times.100] is
less than 200%, since the number of the low refractive index fine
particle existing on the surface of the optical functional layer is
too small, there is a possibility that the preferred effects of the
invention are not obtained. The [(F.sub.Lu/P.sub.Lt).times.100] is
more preferably 230% or more, and further preferably 270% or
more.
[0222] Also, the [(P.sub.Hd/P.sub.Ht).times.100] is desirably 120%
or more. When the [(P.sub.Hd/P.sub.Ht).times.100] is less than
120%, since a large amount of the high refractive index fine
particle is distributed even in an upper part of the optical
functional layer, and the reflectance increases, there is a
possibility that the preferred effects of the invention are not
obtained. The [(P.sub.Hd/P.sub.Ht).times.100] is more preferably
140% or more, and further preferably 160% or more.
[Configuration of Optical Film]
[0223] As described above, the optical film of the invention is an
optical film including a transparent support having thereon the
foregoing optical functional layer as an outermost surface. In
addition to this optical functional layer, the subject optical film
can have other functional layer as an underlying layer, if desired.
Next, the layers configuring the optical film of the invention are
described.
[0224] A preferred embodiment of the optical film of the invention
is described.
[0225] FIG. 4 is a cross-sectional view schematically showing a
layer configuration of a two-layer type optical film having an
excellent antireflection performance according to an embodiment of
the invention. The optical film as shown in FIG. 4 has a layer 15
having hard coat properties (hereinafter referred to as "hard coat
layer") as an underlying layer on a transparent support 11 and has
thereon an optical functional layer 12 (a high refractive index
layer 13 and a low refractive index layer 14 are described in FIG.
4 for the sake of convenience).
[0226] Also, FIG. 5 is a cross-sectional view schematically showing
a layer configuration of a multilayer type optical film having a
more excellent antireflection performance according to an
embodiment of the invention. The optical film as shown in FIG. 5
has a transparent support 11, a layer 15 having hard coat
properties (hereinafter referred to as "hard coat layer") as an
underlying layer, a middle refractive index layer 16 and an optical
functional layer 12 on the outermost surface. It is desirable that
the transparent support 11, the middle reactive index layer 16 and
the high refractive index layer 13 and the low refractive index
layer 14 of the optical functional layer 12 have refractive indexes
satisfying the following relationship.
(Refractive index of high refractive index layer)>(Refractive
index of middle refractive index layer)>(Refractive index of
transparent support)>(Refractive index of low refractive index
layer)
[Transparent Support]
[0227] The support of the optical film of the invention is not
particularly limited, and examples thereof include a transparent
resin film, a transparent resin plate, a transparent resin sheet
and a transparent glass. Examples of the transparent resin film
include a cellulose acylate film (for example, a cellulose
triacetate film (refractive index: 1.48), a cellulose diacetate
film, a cellulose acetate butyrate film and a cellulose acetate
propionate film), a polyethylene terephthalate film, a
polyethersulfone film, a polyacrylic resin film, a polyurethane
based film, a polyester film, a polycarbonate film, a polysulfone
film, a polyether film, a polymethylpentene film, a polyether
ketone film, a (meth)acrylonitrile film and a polymer having an
alicyclic structure (for example, a norbornene based resin (for
example, ARTON: a trade name of JSR Corporation) and an amorphous
polyolefin (for example, ZEONEX: a trade name of Zeon
Corporation)). A thickness of the support which can be used is
usually from about 25 .mu.m to 1,000 .mu.m, preferably from 25
.mu.m to 200 .mu.m, more preferably from 30 .mu.m to 150 .mu.m, and
further preferably from 30 to 90 .mu.m.
[0228] Though a width of the support is arbitrary, in view of
handling, yield and productivity, it is usually from 100 to 5,000
mm, preferably from 800 to 3,000 mm, and more preferably from 1,000
to 2,000 mm.
[0229] It is preferable that the surface of the support is smooth.
A value of an average roughness Ra is preferably not more than 1
.mu.m, more preferably from 0.0001 to 0.5 .mu.m, and further
preferably from 0.001 to 0.1 .mu.m.
[0230] The transparent is preferably a plastic film. Examples of
the plastic film include those made of a cellulose ester (for
example, triacetyl cellulose, diacetyl cellulose, propionyl
cellulose, butyryl cellulose, acetylpropionyl cellulose or
nitrocellulose) or a polyolefin (for example, polypropylene,
polyethylene or polymethylpentene). Of these, triacetyl cellulose
and a polyolefin are preferable for the utility of a polarizing
plate because they are small retardation and high optical
uniformity; and when used for a liquid crystal display device,
triacetyl cellulose is especially preferable.
[Hard Coat Layer]
[0231] In order to impart physical strength of the film, it is
preferable that the optical film of the invention is provided with
a hard coat layer on one surface of the transparent support.
[0232] The refractive index of the hard coat layer in the invention
is preferably in the range of from 1.48 to 1.75, more preferably
from 1.49 to 1.65, and further preferably from 1.50 to 1.55 from
the standpoint of optical design for the purpose of obtaining an
antireflection film. In the invention, it is preferable from the
standpoints of reflectance, tint, unevenness and cost that the
refractive index of the hard coat layer falls within this
range.
[0233] As to a thickness of the hard coat layer, the thickness of
the hard coat layer is usually from about 0.5 .mu.m to 50 .mu.m,
preferably from 1 .mu.m to 30 .mu.m, more preferably from 2 .mu.m
to 20 .mu.m, and most preferably from 3 .mu.m to 15 .mu.m from the
viewpoint of imparting sufficient durability and impact resistance
to the film. It is preferable that the thickness of the hard coat
layer falls within the foregoing range from the standpoints of
curl, productivity and cost.
[0234] Also, the strength of the hard coat layer is preferably H or
more, more preferably 2H or more, further preferably 3H or more,
and most preferably 5H or more by a pencil hardness test.
[0235] Furthermore, it is preferable that an abrasion amount of a
specimen before and after the test is small as far as possible in a
taber test according to JIS K5400.
[0236] Also, a haze to be caused due to the surface scattering of
the optical film of the invention (hereinafter referred to as
"surface haze") is preferably from 0.3% to 20%, more preferably
from 0.5% to 10%, further preferably from 0.5% to 5%, and
especially preferably from 0.5% to 2%. When the surface haze is too
large, the contrast in a bright room is deteriorated, whereas it is
too small, the reflection is deteriorated.
[0237] Also, a haze to be caused due to the internal scattering of
the optical film of the invention (hereinafter referred to as
"internal haze") is preferably from 0% to 60%, more preferably from
1% to 40%, especially preferably from 10% to 35%, and most
preferably from 15% to 30%. When the internal haze is too large,
the frontal contrast is lowered, and a faded feel increases. When
the internal haze is too small, a combination of raw materials
which can be used is restricted, conformity with antiglare
properties and other characteristic values becomes difficult, and
the cost increases.
[0238] The haze of the hard coat layer varies depending upon the
function to be imparted to the optical film.
[0239] In addition to the function to suppress the reflectance of
the surface, in the case of imparting an antiglare function by
surface scattering of the hard coat layer, a surface haze (a value
obtained by subtracting a surface haze value from the total haze
value; and the internal haze value can be measured by eliminating
irregularities of the film surface by a substance having the same
refractive index as in the film surface) is preferably from 0.1% to
20%, more preferably from 0.2% to 10%, further preferably from 0.2%
to 5%, and especially preferably from 0.2% to 2%. When the surface
haze is too large, the contrast in a bright room is deteriorated,
whereas it is too small, the reflection is deteriorated.
[0240] Also, in the case of incorporating a translucent particle in
the hard coat layer to impart internal scattering, a preferred
range of the internal haze varies depending upon the purpose. In
the case of making it hard to view a pattern, color unevenness,
brightness unevenness, glare, etc. of a liquid crystal panel by the
internal scattering or imparting a function to enlarge a viewing
angle by scattering, the internal haze value is preferably from 0%
to 60%, more preferably from 1% to 40%, further preferably from 10%
to 35%, and especially preferably from 15% to 30%. When the
internal haze is too large, the frontal contrast is lowered, and a
faded feel increases. When the internal haze is too small, a
combination of raw materials which can be used is restricted,
conformity with antiglare properties and other characteristic
values becomes difficult, and the cost increases. On the other
hand, in the case of attaching importance to the frontal contrast,
the internal contrast is preferably from 0% to 30%, more preferably
from 1% to 20%, and most preferably from 1% to 10%.
[0241] In the optical film of the invention, it is possible to
freely set up the surface haze and internal haze depending upon the
purpose.
[0242] Also, in the case of imparting an antiglare function by the
surface scattering of the hard coat layer, with respect to the
surface irregular shape of the hard coat layer, it is preferred to
regulate a center line average roughness (Ra) to not more than 0.30
.mu.m. Ra is more preferably 0.01 to 0.20 .mu.m, and more
preferably from 0.01 to 0.12 .mu.m. When Ra is too large, there are
involved problems that a white blur feel due to the surface
scattering appears and uniformity of the layer to be formed on the
hard coat layer is hardly obtained. In the film of the invention,
the surface irregularities of the hard coat layer are dominant for
the surface irregularities of the film. By regulating the center
line average roughness of the hard coat layer, it is possible to
make the center line average roughness of the optical film fall
within the foregoing range. In order to impart an antiglare
function by the surface scattering, a particle having a particle
size of from 1 .mu.m to 50 .mu.m may be added to the hard coat
layer.
[0243] In addition to the regulation of the irregular shape of the
surface, for the purpose of keeping the sharpness of an image, it
is preferred to regulate the transmitted image sharpness. The
transmitted image sharpness of the optical film is preferably 60%
or more. In general, the transmitted image sharpness is an index to
show a blurring degree of an image reflected through the film, and
it is meant that when this value is large, the image to be viewed
through the film is sharp and good. The transmitted image sharpness
is preferably 80% or more, and more preferably 90% or more.
[Middle Refractive Index Layer]
[0244] In the film of the invention, the antireflection properties
can be enhanced by providing a middle refractive index layer. The
refractive index of the middle refractive index layer is preferably
1.55 or more and not more than 1.80.
[0245] The middle refractive index layer which is used in the
invention is composed of a binder (for example, ionizing
radiation-curable polyfunctional monomers or polyfunctional
oligomers) and a high reactive index inorganic fine particle for
the purpose of controlling the refractive index. In the case of
forming the middle refractive index layer in the invention, it is
more preferable that the hard coat layer and the middle refractive
index layer are formed by single coating. That is, it is preferred
to form the hard coat layer and the middle refractive index layer
by single winding up using a coater for simultaneous multilayer
coating; and it is more preferred to simultaneously form the hard
coat layer, the middle refractive index layer and the optical
functional layer.
[0246] In a preferred embodiment of the invention, a coating
composition containing the heat crosslinking or photo crosslinking
fluorine-containing compound, the low refractive index fine
particle (A), the high refractive index fine particle (B) and the
curable compound is coated on the foregoing middle refractive index
layer, thereby simultaneously forming the low refractive index
layer and the high refractive index layer.
[Transparent Conductive Layer]
[0247] In the optical film of the invention, for the antistatic
purpose, it is preferred from the standpoint of destaticization on
the film surface to provide a transparent conductive layer. When it
is required to decrease a surface resistivity value from the
display side, the transparent conductive layer is effective in the
case where contamination on the surface is of a problem. Examples
of a method of forming a transparent conductive layer include known
methods such as a method of coating a conductive coating solution
containing a conductive particle and a reactive curable resin; and
a method of forming a conductive thin film by vapor deposition or
sputtering of a metal or metal oxide capable of forming a
transparent film, etc. In the case of coating, the coating method
is not particularly limited, and an optimum method is selected and
performed among known methods such as roll coating, gravure
coating, bar coating and extrusion coating depending upon the
characteristics and coating amount of the coating solution. The
transparent conductive layer can be formed on the transparent
support or the hard coat layer directly or via a primer layer
capable of strengthening adhesion thereto.
[0248] It is preferred that the surface resistance value (SR) of
the conductive layer satisfies Log SR.gtoreq.12.
[0249] The Log SR is more preferably from 5 to 12, further
preferably from 5 to 9, and most preferably from 5 to 8. The
surface resistivity (SR) of the conductive layer can be measured by
a four probe method or a circular electrode method.
[0250] It is preferable that the conductive layer is substantially
transparent. Specifically, the haze of the conductive layer is
preferably not more than 10%, more preferably not more than 5%,
further preferably not more than 3%, and most preferably not more
than 1%. The transmittance of light having a wavelength of 550 nm
is preferably 50% or more, more preferably 60% or more, further
preferably 65% or more, and most preferably 70% or more.
[Step of Coating Optical Functional Layer]
[0251] The coating composition for forming an optical functional
layer in the invention is one capable of forming an optical
functional layer upon being cured. With respect to the subject
coating composition, in the optical functional layer, the low
refractive index fine particle is arranged substantially in a line
on the surface of the optical functional layer on the opposite side
of the transparent support; and the high refractive index fine
particle is maldistributed in a lower part of the optical
functional layer. Here, the matter that the high refractive index
fine particle is maldistributed in a lower part of the optical
functional layer means that the number of the high refractive index
fine particles existing in a region within 50% on a near side to
the support of the optical functional layer is 60% or more,
preferably 70% or more, and more preferably 80% or more. The
existing state of the high refractive index fine particles can be
confirmed through observation of a slice of the optical film by TEM
(scanning electron microscope). For example, the maldistribution
state of the high refractive index fine particle may be confirmed
by counting the number of fine particles existing within 50% on a
near side to the support of the optical functional layer and the
number of fine particles existing in the whole of the optical
functional layer and comparing the both. In the case where the
interface is not linear, a center line is drawn to form an
interface. In the high refractive index layer, in the case where
the existing proportion of high refractive index fine particles is
low, a reduction of the reflectance of the optical film is small so
that unevenness is easily generated.
[0252] The thickness of the optical functional layer of the
invention is 50 nm or more and not more than 250 nm. It is more
preferably in the range of from 100 to 230 nm, and further
preferably in the range of from 150 to 220 nm. When the thickness
of the optical functional layer is less than 50 nm, since it is
difficult to form a uniform film, unevenness in the thickness is
easily generated, and interference unevenness is easily generated.
When the optical functional layer is thicker than 250 nm, the
optical path length is long so that preferred antireflection
properties are not obtained.
[Production Method of Optical Film]
[0253] Next, the production method of the optical film of the
invention is described.
[0254] The production method of the optical film of the invention
includes a step of coating at least one of a layer-forming
composition for hard coat layer and a layer-forming composition for
middle refractive index layer on a transparent support, as the need
arises; and a step of coating a coating composition for forming an
optical functional layer which is an essential layer. Preferred
examples of the coating composition for forming an optical
functional layer are the same as those described previously. It is
especially preferable that the method does not go through a step of
winding up the transparent support coated between the two
steps.
[0255] The step of coating at least either one of the hard coat
layer and the middle refractive index layer is preferably a step of
extrusion onto the support using a slot die or a step of
simultaneous extrusion onto the support from a coater having two
slots.
[0256] Also, it is preferable that after the step of coating at
least either one of the hard coat layer and the middle refractive
index layer and the step of coating the optical functional layer, a
step of drying and a step of curing are carried out at least one
time.
[0257] In the case where plural functional layers are formed in
addition to the optical functional layer, it is possible to form
every layer for the respective layers by carrying out sending,
layer formation and winding up in the necessary layer number.
However, it is advantageous in view of productivity and cost to
form all of the layers in a single step by providing a set of a
coating station and a drying and curing zone in the same number as
the number of layers in parallel during the stage of from sending
of the transparent support to winding up.
[0258] In the optical film of the invention, since the optical
functional layer is formed by single coating, in comparison with a
production method of forming the high refractive index layer and
the low refractive index layer in a separate step from each other,
the number of the set of a coating station and a drying and curing
zone can be reduced by one, and a large merit is obtained from the
standpoint of equipment. For example, in the case of forming four
layers of the hard coat layer, the middle refractive index layer,
the high refractive index layer and the low refractive index layer
on the transparent support, when the technology of the invention is
adopted, the hard coat layer and the middle refractive index layer
can be formed on the transparent support, and the optical
functional layer can be further formed; it is enough to arrange
three sets of a coating station and a drying and curing zone during
the stage of from sending of the transparent support to winding up,
thereby bringing effects in view of productivity and costs. Also,
by adopting a technology for simultaneously forming the hard coat
layer and the middle refractive index layer, it is enough to
arrange two sets of a coating station and a drying and curing zone
during the stage of from sending of the transparent support to
winding up, thereby bringing a very significant effect.
[0259] The respective steps are hereunder described in greater
detail.
[0260] In coating step, it is more preferred to perform coating
using a slot die having plural slots. For example, by using a slot
die having two slots and simultaneously extruding a coating
composition for the optical functional layer and a coating
composition for simultaneously forming the hard coat layer and the
middle refractive index layer onto the transparent support from the
separate slots, these layers can be simultaneously formed. Even by
using a coating machine having only one set of a coating station
and a drying and curing zone, an optical film can be obtained by
single coating, thereby bringing a more significant effect.
[0261] The optical functional layer and the functional layer in the
optical film of the invention can be formed in the following
coating method, but it should not be construed that the invention
is limited to this method.
[0262] There are adopted known methods such as a dip coating
method, an air knife coating method, a curtain coating method, a
roller coating method, a wire bar coating method, a gravure coating
method, an extrusion coating method (die coating method) (see U.S.
Pat. No. 2,681,294) and a microgravure coating method. Of these, a
microgravure coating method and a die coating method are
preferable; and a die coating method is especially preferable.
[0263] The "microgravure coating method" as referred to herein,
which is adopted in the invention, is a coating method which is
characterized by disposing a gravure roll having a diameter of from
about 10 to 100 mm, and preferably from about 20 to 50 mm and
engraved with a gravure pattern over the entire periphery thereof
beneath the support and simultaneously revolving the gravure roll
in an inverse direction to the conveyance direction of the support
and scraping away the excessive coating solution from the surface
of the subject gravure roll by a doctor blade and transferring a
fixed amount of the coating solution onto a lower surface of the
support in a position at which the upper surface of the support is
in a free state, thereby achieving coating.
[Extrusion Step onto Support Using a Slot Die]
[0264] In order to feed the film of the invention with high
productivity, an extrusion method (die coating method) is
preferably adopted.
[0265] In particular, with respect to a die coater which can be
preferably used in a region where the wet coating amount is low
(not more than 20 cc/m.sup.2), such as the hard coat layer and the
antireflection layer, JP-A-2007-293313 can be made hereof by
reference.
[0266] In the invention, in a process for coating the coating
composition on the support and drying it, the coating composition
capable of spontaneously segregating the low refractive index fine
particle in the coating composition on the uppermost surface side
and spontaneously segregating the high refractive index fine
particle in the coating composition on the interface side of the
support side, respectively is formed, whereby the object is
attained. For the purpose of more effectively segregating the added
low refractive index fine particle and high refractive index fine
particle on the respective surface sides, it is also possible to
divide the component which is maldistributed on the surface side
and the component which is segregated on the interface side of the
support side from each other and to stack and coat the respective
compositions simultaneously or substantially simultaneously by a
coating device having two coating heads (for example, see FIGS. 6A
and 6B of JP-A-2007-293313) or the like. In that case, since
coating is carried out by previously dividing the coating
composition into two liquids, it is easy to carry out the
segregation, and as a result, a cohesion defect of the particle in
a fine region, or the like is reduced. Thus, not only an
enhancement of the antireflection performance or scratch resistance
can be expected, but even in the case of a large area, a layer
which is stable and free from unevenness can be formed.
[0267] That is, a method including coating, on a transparent
support, a curable composition 1 containing a low refractive index
fine particle having a refractive index of not more than 1.45 and a
fluorine-containing compound and a curable composition 2 containing
a high refractive index fine particle having a refractive index of
1.55 or more using a coating device including at least member
selected from adjacent two slot dies and a slide-type coating head
while supporting the transparent support by backup rollers and
travelling it, and curing the curable compositions 1 and 2 to form
an optical functional layer having a thickness of 50 nm or more and
not more than 250 nm is also preferable as the method for producing
the optical film of the invention.
[Protective Film for Polarizing Plate]
[0268] In the case of using the optical film of the invention for a
liquid crystal display device, in preparing a polarizing plate, the
optical film is used as a surface protective film for polarizing
film (protective film for polarizing plate). Accordingly, it is
preferred to improve the adhesion to the polarizing film containing
polyvinyl alcohol as a major component by hydrophilizing the
surface of the transparent support on the opposite side to the side
having the optical functional layer, namely the surface on the side
to which the polarizing film is stuck.
[0269] It is especially preferred to use a triacetyl cellulose film
as the transparent support. As the method of preparing a protective
film for polarizing plate in the invention, there may be considered
two methods including (1) a method in which each layer (for
example, the hard coat layer, the middle refractive index layer,
the optical functional layer, etc.) is coated on one surface of the
transparent support having been previously subjected to a
saponification treatment; and (2) a method in which after coating
each of the foregoing layers on one surface of the transparent
support, the side to which the polarizing film is struck is
subjected to a saponification treatment. However, in the method
(1), since even the surface on which a hard coat layer is to be
coated is hydrophilized, it is difficult to ensure the adhesion
between the support and the hard coat layer. Therefore, the method
(2) is preferable.
[Saponification Treatment]
(1) Dipping Method:
[0270] This method is a measure in which the optical film is dipped
in an alkaline solution, thereby saponifying all of the surfaces
having reactivity with an alkali on the entire surface of the film.
Since this method does not require special equipment, it is
preferable from the viewpoint of cost. A sodium hydroxide aqueous
solution is preferable as the alkaline solution. A concentration of
the alkaline solution is preferably from 0.5 to 3 moles/L, and
especially preferably from 1 to 2 moles/L; and a liquid temperature
of the alkaline solution is preferably from 30 to 70.degree. C.,
and especially preferably from 40 to 60.degree. C.
[0271] Though the foregoing combination of the saponification
condition is a combination of relatively mild conditions, it can be
set up by the raw materials and configuration of the optical film
and a desired contact angle.
[0272] After dipping in the alkaline solution, it is preferable
that the film is thoroughly washed with water or that the film is
dipped in a dilute acid, thereby neutralizing an alkaline component
such that the alkaline component does not remain in the film.
[0273] By the saponification treatment, the surface of the
transparent support opposite to the surface on which the optical
functional layer is provided is hydrophilized. The protective film
for polarizing plate is provided for use after making the
hydrophilized surface of the transparent support adhere to the
polarizing film.
[0274] The hydrophilized surface is effective for improving the
adhesion to the adhesive surface made of, as a major component,
polyvinyl alcohol.
[0275] With respect to the saponification treatment, it is
preferable from the viewpoint of adhesion to the polarizing film
that the contact angle of the surface of the transparent support in
the opposite side to the side at which the optical functional layer
is provided against water is low as far as possible. On the other
hand, in the dipping method, since even the surface having the
optical functional layer thereon is damaged by the alkali at the
same time over, it is important to adopt a necessary and minimum
reaction condition. In the case where the contact angle of the
transparent support on the surface in the opposite side to the side
at which the optical functional layer is provided, namely the
sticking surface of the optical film, against water is employed as
an index of the damage which the antireflection layer receives by
the alkali, especially when the transparent support is triacetyl
cellulose, the contact angle is preferably from 20.degree. to
50.degree., more preferably from 30.degree. to 50.degree., and
further preferably from 40.degree. to 50.degree.. When the contact
angle is not more than 50.degree., a problem of adhesion to the
polarizing film is not caused, and therefore, such is preferable.
On the other hand, when the contact angle is 20.degree. or more,
the damage which the optical functional layer receives is not
large, the physical strength and light fastness are not hindered,
and therefore, such is preferable.
(2) Method of Coating an Alkaline Solution:
[0276] As a measure for avoiding the damage against the optical
functional layer in the foregoing dipping method, there is
preferably adopted a method of coating an alkaline solution by
coating an alkaline solution only on the surface on the opposite
side to the surface on which the optical functional layer is
provided, followed by heating, washing with water and drying. In
that case, the "coating" as referred to herein means that the
alkaline solution or the like is brought into contact with only the
surface on which the saponification is carried out. At that time,
it is preferred to carry out the saponification treatment such that
the contact angle of the sticking surface of the optical film
against water is from 10.degree. to 50.degree.. Also, in addition
to the coating, spraying, contacting with a liquid-containing belt,
or other means is also included. By adopting such a method, since
equipment and step for coating the alkaline solution are separately
required, this method is inferior to the dipping method (1) from
the viewpoint of cost. On the other hand, since the alkaline
solution comes into contact with only the surface to which the
saponification treatment is applied, a layer using a raw material
which is weak against the alkaline solution can be provided on the
surface on the opposite side. For example, in a vapor deposited
film or a sol-gel film, a variety of influences such as corrosion,
dissolution and peeling are caused due to the alkaline solution.
Accordingly, though it is not desired to provide such a vapor
deposited film or sol-gel film by the dipping method, since the
film does not come into contact with the solution in this coating
method, it is possible to use such a vapor deposited film or a
sol-gel film without any problem.
[0277] In all of the foregoing saponification methods (1) and (2),
since the saponification can be carried out after winding out the
film from the support in a rolled state and forming the respective
layers, it may be added after the optical film production step and
achieved in a series of operations. Furthermore, by continuously
carrying out a sticking step to a polarizing plate made of a
similarly wound out support collectively, it is possible to prepare
a polarizing plate with good efficiency as compared with the case
of carrying out the same operations sheet by sheet.
[Antireflection Film]
[0278] Since the optical film of the invention is excellent in the
antireflection performance, it can be used as an antireflection
film. The subject antireflection film can also be used as a
protective film for polarizing plate, or the like.
[Polarizing Plate]
[0279] The polarizing plate of the invention is a polarizing plate
having a polarizing film and two protective films for protecting
the both surfaces on the front and back sides of the subject
polarizing film. At least one of the protective films is the
foregoing optical film of the invention.
[0280] The transparent support and the polarizing film can be
adhered to each other via an adhesive layer or a pressure sensitive
adhesive layer made of polyvinyl alcohol.
[0281] By using the optical film of the invention as a protective
film for polarizing plate, a polarizing plate having physical
strength and an excellent antireflection function can be prepared,
and it is possible to largely reduce the cost.
[0282] Also, by preparing a polarizing plate using the optical film
of the invention for one of the protective films for polarizing
plate and an optically-compensatory film having optical anisotropy
as described later for the other protective film of the polarizing
film, respectively, it is possible to prepare a polarizing plate
having improved contrast of a liquid crystal display device in a
bright room and capable of extremely widening a viewing angle in
the up and down, left and right directions and the oblique
direction.
[Optically-Compensatory Film]
[0283] An optically-compensatory film (retardation film) is able to
improve a viewing angle characteristic of a liquid crystal display
screen.
[0284] Known optically-compensatory films can be used as the
optically-compensatory film. An optically-compensatory film having
a layer having optical anisotropy and containing a compound having
a discotic structural unit and characterized in that an angle
formed by the subject discotic compound and the support varies
following a distance from the transparent support, as described in
JP-A-2001-100042, is preferable from the standpoint of widening a
viewing angle.
[0285] It is preferable that the subject angle increases with an
increase of the distance of the optically-anisotropic layer from
the side of the support surface.
[0286] In the case of using the optically-compensatory film as a
protective film for polarizing film, it is preferable that the
surface on the side to which the polarizing film is to be stuck is
subjected to a saponification treatment. It is preferable that this
saponification is carried out according to the foregoing
saponification treatment.
[0287] Also, an embodiment in which the optically-anisotropic layer
further contains a cellulose ester; an embodiment in which an
oriented film is provided between the optically-anisotropic layer
and the transparent support; and an embodiment in which the
transparent support of the optically-compensatory film having the
optically-anisotropic layer has optically-negative uniaxiality, has
an optical axis in a normal direction of the transparent support
surface and further satisfies the following condition are also
preferable.
20.ltoreq.{(nx+ny)/2-nz}.times.d.ltoreq.400
[0288] In the foregoing conditional expression, nx represents a
refractive index of a slow axis direction in the film plane (a
direction where the refractive index is maximum); ny represents a
refractive index in a fast axis direction (a direction where the
refractive index is minimum); nz represents a refractive index in a
thickness direction of the film; and d represents a thickness of
the optically-compensatory layer.
[Image Display Device]
[0289] The image display device of the invention has at least one
of the optical film of the invention and the polarizing plate of
the invention.
[0290] Examples of the image display device having the optical film
of the invention include a liquid crystal display device (LCD), a
plasma display panel (PDP), an electroluminescence display device
(OLED), a cathode ray tube display device (CRT), a field emission
display (FED) and a surface-conduction electron-emitter display
(SED). Examples of the image display device having a polarizing
plate having the optical film of the invention include image
display devices such as a liquid crystal display device (LCD) and
an electroluminescence display device (OLED). The image display
device of the invention is used by adhering the polarizing plate
having the optical film of the invention to a glass of a liquid
crystal cell of the image display device directly or via other
layer.
[0291] The polarizing plate using the optical film which is used in
the invention can be preferably used for transmission type,
reflection type or semi-transmission type liquid crystal display
devices of a twisted nematic (TN) mode, a super twisted nematic
(STN) mode, a vertical alignment (VA) mode, an in-plane switching
(IPS) mode, an optically-compensatory bend cell (OCB) mode, or the
like.
[0292] Also, when used for a transmission type or semi-transmission
type liquid crystal display device, a display device having higher
visibility can be obtained using a commercially available
brightness enhancing film (a polarizing separation film having a
polarizing selective layer; for example, D-BEF, manufactured by
Sumitomo 3M Limited, etc.) in combination.
[0293] Also, a combination with a .lamda./4 plate can be used for
reducing reflected light from the surface and the inside as a
polarizing plate for reflection type liquid crystal or a surface
protective plate for OLED.
EXAMPLES
[0294] In order to explain the invention in detail, the invention
is hereunder described with reference to the following Examples,
but it should not be construed that the invention is limited
thereto. All "parts" and "%" are on a mass basis unless otherwise
indicated.
(Synthesis of Perfluoroolefin Copolymer (P1))
TABLE-US-00001 [0295] Perfluoroolefin copolymer (P1) ##STR00006##
##STR00007## x y m L1 X 40 10 1 *--CH.sub.2CH.sub.2O--** H
[0296] In a stainless steel-made stirrer autoclave having an
internal volume of 100 mL, 40 mL of ethyl acetate, 14.7 g of
hydroxyethyl vinyl ether and 0.55 g of dilauroyl peroxide were
charged, and the system was deaerated and purged with a nitrogen
gas. 25 g of hexafluoropropylene (HFP) was further introduced into
the autoclave, and the temperature was raised to 65.degree. C. A
pressure at a point of time when the temperature in the autoclave
reached 65.degree. C. was 0.53 MPa (5.4 kg/cm.sup.2). The reaction
was continued for 8 hours while keeping the subject temperature;
and at a point of time when the pressure reached 0.31 MPa (3.2
kg/cm.sup.2), heating was stopped, and the system was allowed to
stand for cooling. At a point of time when the inner temperature
decreased to room temperature, the unreacted monomers were
expelled, the autoclave was opened, and the reaction solution was
taken out. The obtained reaction solution was thrown into an excess
of hexane, and a polymer precipitated by decantation for removal of
the solvent was taken out. Furthermore, this polymer was dissolved
in a small amount of ethyl acetate, and the solution was subjected
to reprecipitation from hexane twice, thereby completely removing
the residual monomers. After drying, 28 g of a polymer was
obtained. Subsequently, 20 g of the subject polymer was dissolved
in 100 mL of N,N-dimethylacetamide, 10.3 g of acrylyl chloride was
added dropwise under ice cooling, and the mixture was then stirred
at room temperature for 10 hours. Ethyl acetate was added to the
reaction solution; the mixture was washed with water; an organic
layer was extracted and then concentrated; and the obtained polymer
was reprecipitated from hexane to obtain 19 g of a perfluoroolefin
copolymer (P1). The obtained polymer had a refractive index of
1.421.
(Preparation of Sol Solution A)
[0297] In a reactor equipped with a stirrer and a reflux condenser,
120 parts of methyl ethyl ketone (MEK), 100 parts of
acryloyloxypropyltrimethoxysilane (KBM-5103, manufactured by
Shin-Etsu Chemical Co., Ltd.) and 3 parts of diisopropoxyaluminum
ethyl acetoacetate were added and mixed. After adding 30 parts of
ion exchanged water, the mixture was allowed to react at 60.degree.
C. for 4 hours, and the reaction mixture was cooled to room
temperature to obtain a sol solution a. The sol solution a had a
mass average molecular weight of 1,600, and among components
including oligomer or polymer components, components having a
molecular weight of from 1,000 to 20,000 accounted for 100%.
Furthermore, as a result of gas chromatographic analysis, the raw
material acryloyloxypropyltrimethoxysilane did not remain at
all.
(Preparation of Silica Dispersion A)
[0298] To 500 parts of a hollow silica fine particle sol (a silica
sol in isopropyl alcohol, average particle size: 40 nm, shell
thickness: 6 nm, silica concentration: 20% by mass, refractive
index of silica particle: 1.30; as prepared by changing the size in
conformity to Preparation Example 4 of JP-A-2002-79616), 10 parts
of acryloyloxypropyltrimethoxysilane (manufactured by Shin-Etsu
Chemical Co., Ltd.) and 1.5 parts of diisopropoxyaluminum ethyl
acetate were added and mixed, to which was then added 9 parts of
ion exchanged water. After allowing the mixture to react at
60.degree. C. for 8 hours, the reaction mixture was cooled to room
temperature, to which was then added 1.8 parts of acetyl
acetone.
[0299] Solvent substitution was carried out by distillation in
vacuo under a pressure of 20 kPa while adding cyclohexanone to 500
g of this dispersion such that the content of silica became
substantially constant. The dispersion was free from the generation
of a foreign substance. When the solids concentration was regulated
with cyclohexanone to 22% by mass, the viscosity was found to be 9
mPas at 25.degree. C. The residual amount of isopropyl alcohol in
the obtained silica dispersion A was analyzed by gas
chromatography. As a result, it was found to be 1.0%.
(Preparation of Silica Dispersion B): Silica Sol Modified with
Fluorine-Containing Modifier
[0300] To 500 parts of a hollow silica fine particle sol (a silica
sol in isopropyl alcohol, average particle size: 40 nm, shell
thickness: 6 nm, silica concentration: 20% by mass, refractive
index of silica particle: 1.30; as prepared by changing the size in
conformity to Preparation Example 4 of JP-A-2002-79616), 8 parts of
acryloyloxypropyltrimethoxysilane (manufactured by Shin-Etsu
Chemical Co., Ltd.), 2 parts of tridecafluorooctyltrimethoxysilane
(manufactured by GE Toshiba Silicone Co., Ltd.) and 1.5 parts of
diisopropoxyaluminum ethyl acetate were added and mixed, to which
was then added 9 parts of ion exchanged water. After allowing the
mixture to react at 60.degree. C. for 8 hours, the reaction mixture
was cooled to room temperature, to which was then added 1.8 g of
acetyl acetone.
[0301] Solvent substitution was carried out by distillation in
vacuo under a pressure of 20 kPa while adding cyclohexanone to 500
g of this dispersion such that the content of silica became
substantially constant. The dispersion was free from the generation
of a foreign substance. When the solids concentration was regulated
with cyclohexanone at 22% by mass, the viscosity was found to be 9
mPas at 25.degree. C. The residual amount of isopropyl alcohol in
the obtained silica dispersion B was analyzed by gas
chromatography. As a result, it was found to be 1.0%.
(Preparation of Dispersion C)
[0302] To 500 g of a methyl isobutyl ketone dispersion of a ZrO2
particle having an average particle size of 15 nm (refractive index
of ZrO.sub.2 particle: 2.4, solids concentration 20% by mass), 10 g
of acryloyloxypropyltrimethoxysilane (manufactured by Shin-Etsu
Chemical Co., Ltd.) and 0.5 parts of diisopropoxyaluminum ethyl
acetate were added and mixed, to which was then added 3 g of ion
exchanged water. After allowing the mixture to react at 60.degree.
C. for 8 hours, the reaction mixture was cooled to room
temperature, to which was then added 1.8 g of acetyl acetone,
thereby preparing a dispersion C. 31.4 g of a mixture of
dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate
(DPHA, manufactured by Nippon Kayaku Co., Ltd.) was added to the
dispersion C, and the mixture was distilled in vacuo under a
pressure of 20 kPa to prepare a solution having a solids
concentration of 62%. 0.5 g of a photopolymerization initiator
(IRGACURE 184, manufactured by Ciba Japan K.K.) and 0.5 g of a
photopolymerization initiator (IRGACURE 904, manufactured by Ciba
Japan K.K.) were added, and the mixture was stirred for
dissolution. The concentration was regulated by the addition of
methyl ethyl ketone, thereby preparing a dispersion C having a
solids concentration of about 61% and a ZrO.sub.2 content in the
solid of about 70%.
(Preparation of Coating Solution a for Hard Coat Layer)
[0303] 306 parts by mass of a mixture of dipentaerythritol
pentaacrylate and dipentaerythritol hexaacrylate (DPHA,
manufactured by Nippon Kayaku Co., Ltd.) was dissolved in a mixed
solvent of 16 parts by mass of methyl ethyl ketone and 220 parts by
mass of cyclohexanone. To the obtained solution, 7.5 parts by mass
of a photopolymerization initiator (IRGACURE 184, manufactured by
Ciba Japan K.K.) was added, and the mixture was stirred until it
was dissolved. Thereafter, 450 parts by mass of MEK-ST (a methyl
ethyl ketone dispersion of an SiO.sub.2 sol having an average
particle size of from 10 to 20 nm and a solids concentration of 30%
by mass, manufactured by Nissan Chemical Industries, Ltd.) was
added, and the mixture was stirred. The resulting mixture was
filtered through a polypropylene-made filter (PPE-03) having a pore
size of 3 .mu.m, thereby preparing a coating solution A for hard
coat layer. A coating film obtained by coating this solution and
curing with ultraviolet rays had a refractive index of 1.50.
(Preparation of Coating Solution B for Hard Coat Layer)
[0304] 71.2 g of a mixture of dipentaerythritol triacrylate and
pentaerythritol tetraacrylate (PET-30, manufactured by Nippon
Kayaku Co., Ltd.), 2.9 g of a polymerization initiator (IRGACURE
184, manufactured by Ciba Japan K.K.), 0.1 g of a fluorine based
surface modifier (SP-13) and 11.8 g of a silane coupling agent
(KBM-5103, manufactured by Shin-Etsu Chemical Co., Ltd.) were added
in methyl isobutyl ketone (MIBK), and the mixture was stirred for
60 minutes by an air disper, thereby completely dissolving the
solutes. A coating film obtained by coating this solution and
curing with ultraviolet rays had a refractive index of 1.52. 13.7 g
of a crosslinked poly(acryl-styrene) particle having an average
particle size of 3.5 .mu.m (copolymerization composition ratio:
50/50, refractive index: 1.536) was dispersed by a Polytron
dispersing machine at 10,000 rpm for 20 minutes, and the obtained
dispersion was added as a 30% methyl isobutyl ketone dispersion.
Methyl isobutyl ketone and methyl ethyl ketone were then added to
regulate the solids concentration to 45% by mass. Thereafter, the
mixture was stirred for 10 minutes by an air disper. A ratio of
methyl isobutyl ketone to methyl ethyl ketone was regulated to
9/1.
[0305] The foregoing mixed solution was filtered through a
polypropylene-made filter having a pore size of 30 .mu.m, thereby
preparing a coating solution B for hard coat layer.
[0306] SP-13: Fluorine based surfactant (used after dissolving as a
10% by mass solution in MEK)
##STR00008##
(Preparation of Coating Solution a for Middle Refractive Index
Layer)
[0307] To 65.5 g of the dispersion C, 57 g of a mixture of
dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate
(DPHA, manufactured by Nippon Kayaku Co., Ltd.) and 3 g of a
photopolymerization initiator (IRGACURE 904, manufactured by Ciba
Japan K.K.); methyl isobutyl ketone was added such that the solids
concentration was 3.5% by mass; and the mixture was stirred for 10
minutes. A coating film obtained by coating this solution and
curing with ultraviolet rays had a refractive index of 1.62.
[0308] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.M, thereby preparing a
coating solution A for middle refractive index layer.
(Preparation of Coating Solution B for Middle Refractive Index
Layer)
[0309] To 20.0 parts of a commercially available conductive fine
particle ATO (antimony-doped tin oxide T-1) (specific surface area:
80 m.sup.2/g, manufactured by Mitsubishi Materials Corporation),
6.0 parts of the following dispersant (B-1) having an anionic group
and a methacryloyl group and 74 parts of methyl isobutyl ketone
were added, and the mixture was stirred.
##STR00009##
[0310] The ATO particle in the foregoing solution was dispersed
using a media dispersion machine (using zirconia beads having a
diameter of 0.1 mm). The mass average particle size of the ATO
particle in the dispersion was evaluated by a light scattering
method. As a result, it was found to be 55 nm. There was thus
prepared an ATO dispersion.
[0311] To 100 parts of the foregoing ATO dispersion, 6 parts of a
mixture of dipentaerythritol pentaacrylate and dipentaerythritol
hexaacrylate (DPHA, manufactured by Nippon Kayaku Co., Ltd.) and
0.8 parts of a polymerization initiator (IRGACURE 184, manufactured
by Ciba Japan K.K.) were added, and the mixture was stirred. There
was thus prepared a coating solution B for middle refractive index
layer. A coating film obtained from this paint had a refractive
index of 1.62.
(Preparation of Coating Solution a for Optical Functional
Layer)
[0312] To 132 g of the dispersion C, 31.5 g of the perfluoroolefin
copolymer (P1), 81.8 g of the silica dispersion A, 1.6 g of
reactive silicone X-22-164B (a trade name of Shin-Etsu Chemical
Co., Ltd.), 7.2 g of the sol solution a and 1.6 g of a
photopolymerization initiator (IRGACURE 907 (a trade name),
manufactured by Ciba Japan K.K.); methyl ethyl ketone and
cyclohexanone were added such that the solids concentration was
5.4%; and the mixture was stirred for 10 minutes. A mass ratio of
methyl ethyl ketone to cyclohexanone was regulated to 8/2.
[0313] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.m, thereby preparing a
coating solution A for optical functional layer.
(Preparation of Coating Solution B for Optical Functional
Layer)
[0314] To 132 g of the dispersion C, 28.7 g of the perfluoroolefin
copolymer (P1), 94.4 g of the silica dispersion A, 1.6 g of
reactive silicone X-22-164B (a trade name of Shin-Etsu Chemical
Co., Ltd.), 7.2 g of the sol solution a and 1.6 g of a
photopolymerization initiator (IRGACURE 907 (a trade name),
manufactured by Ciba Japan K.K.); methyl ethyl ketone and
cyclohexanone were added such that the solids concentration was
5.4%; and the mixture was stirred for 10 minutes. A mass ratio of
methyl ethyl ketone to cyclohexanone was regulated to 8/2.
[0315] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.m, thereby preparing a
coating solution B for optical functional layer.
(Preparation of Coating Solution C for Optical Functional
Layer)
[0316] To 132 g of the dispersion C, 19.0 g of the perfluoroolefin
copolymer (P1), 138.4 g of the silica dispersion A, 1.6 g of
reactive silicone X-22-164B (a trade name of Shin-Etsu Chemical
Co., Ltd.), 7.2 g of the sol solution a and 1.6 g of a
photopolymerization initiator (IRGACURE 907 (a trade name),
manufactured by Ciba Japan K.K.); methyl ethyl ketone and
cyclohexanone were added such that the solids concentration was
5.4%; and the mixture was stirred for 10 minutes. A mass ratio of
methyl ethyl ketone to cyclohexanone was regulated to 8/2.
[0317] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.m, thereby preparing a
coating solution C for optical functional layer.
(Preparation of Coating Solution D for Optical Functional
Layer)
[0318] To 132 g of the dispersion C, 31.5 g of the perfluoroolefin
copolymer (P1), 11.1 g of a mixture of dipentaerythritol
pentaacrylate and dipentaerythritol hexaacrylate (DPHA,
manufactured by Nippon Kayaku Co., Ltd.), 31.5 g of the silica
dispersion A, 1.6 g of reactive silicone X-22-164B (a trade name of
Shin-Etsu Chemical Co., Ltd.), 7.2 g of the sol solution a and 1.6
g of a photopolymerization initiator (IRGACURE 907 (a trade name),
manufactured by Ciba Japan K.K.); methyl ethyl ketone and
cyclohexanone were added such that the solids concentration was
5.4%; and the mixture was stirred for 10 minutes. A mass ratio of
methyl ethyl ketone to cyclohexanone was regulated to 8/2.
[0319] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.m, thereby preparing a
coating solution D for optical functional layer.
(Preparation of Coating Solution E for Optical Functional
Layer)
[0320] To 132 g of the dispersion C, 31.5 g of the perfluoroolefin
copolymer (P1), 15.2 g of a mixture of dipentaerythritol
pentaacrylate and dipentaerythritol hexaacrylate (DPHA,
manufactured by Nippon Kayaku Co., Ltd.), 12.6 g of the silica
dispersion A, 1.6 g of reactive silicone X-22-164B (a trade name of
Shin-Etsu Chemical Co., Ltd.), 7.2 g of the sol solution a and 1.6
g of a photopolymerization initiator (IRGACURE 907 (a trade name),
manufactured by Ciba Japan K.K.); methyl ethyl ketone and
cyclohexanone were added such that the solids concentration was
5.4%; and the mixture was stirred for 10 minutes. A mass ratio of
methyl ethyl ketone to cyclohexanone was regulated to 8/2.
[0321] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.m, thereby preparing a
coating solution E for optical functional layer.
(Preparation of Coating Solution F for Optical Functional
Layer)
[0322] A coating solution F for optical functional layer was
prepared in the same manner as in the coating solution A for
optical functional layer, except for replacing the silica
dispersion A with 18.8 g of a mixture of dipentaerythritol
pentaacrylate and dipentaerythritol hexaacrylate (DPHA,
manufactured by Nippon Kayaku Co., Ltd.).
(Preparation of Coating Solution G for Optical Functional
Layer)
[0323] A coating solution G for optical functional layer was
prepared in the same manner as in the coating solution A for
optical functional layer, except for replacing the silica
dispersion A with 90.0 g of a hollow silica fine particle sol (a
silica sol in isopropyl alcohol, average particle size: 40 nm,
shell thickness: 6 nm, silica concentration: 20% by mass,
refractive index of silica particle: 1.30).
(Preparation of Coating Solution H for Optical Functional
Layer)
[0324] A coating solution H for optical functional layer was
prepared in the same manner as in the coating solution A for
optical functional layer, except for replacing the silica
dispersion A with the same amount of the silica dispersion B.
(Preparation of Coating Solution I for Optical Functional
Layer)
[0325] A coating solution I for optical functional layer was
prepared in the same manner as in the coating solution A for
optical functional layer, except for replacing the dispersion C
with 80.5 g of a mixture of dipentaerythritol pentaacrylate and
dipentaerythritol hexaacrylate (DPHA, manufactured by Nippon Kayaku
Co., Ltd.).
(Preparation of Coating Solution J for Optical Functional
Layer)
[0326] A coating solution J for optical functional layer was
prepared in the same manner as in the coating solution A for
optical functional layer, except for replacing the perfluoroolefin
copolymer (P1) with the same amount of a mixture of
dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate
(DPHA, manufactured by Nippon Kayaku Co., Ltd.).
(Preparation of Coating Solution K for Optical Functional
Layer)
[0327] 31.5 g of the perfluoroolefin copolymer (P1), 12.6 g of the
silica dispersion A, 0.8 g of reactive silicone X-22-164B (a trade
name of Shin-Etsu Chemical Co., Ltd.), 3.6 g of the sol solution a
and 0.8 g of a photopolymerization initiator (IRGACURE 907 (a trade
name), manufactured by Ciba Japan K.K.) were added; methyl ethyl
ketone and cyclohexanone were added such that the solids
concentration was 3.6%; and the mixture was stirred for 10 minutes.
A mass ratio of methyl ethyl ketone to cyclohexanone was regulated
to 8/2.
[0328] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 .mu.m, thereby preparing a
coating solution K for optical functional layer.
(Preparation of Coating Solution L for Optical Functional
Layer)
[0329] To 132 g of the dispersion C, 11.1 g of a mixture of
dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate
(DPHA, manufactured by Nippon Kayaku Co., Ltd.), 0.8 g of reactive
silicone X-22-164B (a trade name of Shin-Etsu Chemical Co., Ltd.),
3.6 g of the sol solution a and 0.8 g of a photopolymerization
initiator (IRGACURE 907 (a trade name), manufactured by Ciba Japan
K.K.) were added; methyl ethyl ketone and cyclohexanone were added
such that the solids concentration was 5.4%; and the mixture was
stirred for 10 minutes. A mass ratio of methyl ethyl ketone to
cyclohexanone was regulated to 8/2.
[0330] The mixed solution was filtered through a polypropylene-made
filter (PPE-03) having a pore size of 3 pin, thereby preparing a
coating solution L for optical functional layer.
Example 1
Preparation of Optical Film
(Preparation of Optical Film 1-1A)
[0331] The foregoing coating solution A for hard coat layer was
coated on a triacetyl cellulose film having a thickness of 80 .mu.m
(TAC-TA80U, manufactured by FUJIFILM Corporation; refractive index:
1.49) using a slot die coater (the coater as shown in FIG. 3(A) of
JP-A-2007-293313) and dried at 100.degree. C. for 2 minutes.
Subsequently, purge with nitrogen was carried out, and ultraviolet
rays were irradiated at 70 mJ/cm.sup.2 under a condition in an
oxygen concentration of 0.1% to cure the coated layer, thereby
forming a hard coat layer (refractive index: 1.50, thickness: 6
.mu.m). Subsequently, the foregoing coating composition A for
middle refractive index layer was coated using a slot die coater
(the coater as shown in FIG. 3(A) of JP-A-2007-293313) and dried at
100.degree. C. Thereafter, purge with nitrogen was carried out, and
ultraviolet rays were irradiated at 200 mJ/cm.sup.2 under a
condition in an oxygen concentration of 0.1% to cure the coated
layer, thereby providing a middle refractive index layer
(refractive index: 1.62, thickness: 60 nm). Subsequently, the
foregoing coating composition A for optical functional layer was
coated on the middle refractive index layer using a slot die coater
(the coater as shown in FIG. 3(A) of JP-A-2007-293313) and dried at
100.degree. C. for one minute. Thereafter, purge with nitrogen was
carried out, and ultraviolet rays were irradiated at 500
mJ/cm.sup.2 under a condition in an oxygen concentration of 0.05%
to cure the coated layer, thereby simultaneously forming a high
refractive index layer and a low refractive index layer. There was
thus prepared an optical film 1-1A. As a result of observation of a
slice of the formed film by TEM, a state in which the hollow silica
fine particle was arranged in a line on the surface, and a zirconia
fine particle was maldistributed in a lower part could be
confirmed. A thickness of each of the low refractive index layer
and the high refractive index layer of the obtained optical
functional layer was measured from the foregoing TEM image of the
cross section. As a result, the high refractive index layer and the
low refractive index layer had a thickness of 110 nm and 95 nm,
respectively.
(Preparation of Optical Films 1-1B to 1-1F)
[0332] Optical films 1-1B to 1-1F were each prepared in the same
manner as in the optical film 1-1A, except for using the coating
solutions B to F for optical functional layer, respectively as the
coating solution for optical functional layer. A slice of each of
the formed films was observed by TEM. As a result, in 1-1B, 1-1D,
1-1E and 1-1F a state in which a zirconia fine particle was
maldistributed in a lower part could be confirmed. Furthermore, in
1-1B, 1-1D and 1-1E, a state in which the hollow silica fine
particle was arranged in a line on the surface could also be
confirmed. On the other hand, in 1-1C, in addition to the hollow
silica fine particle arranged in a line on the surface, it was
observed that the hollow silica fine particle also cohered in the
zirconia fine particle maldistributed in a lower part.
(Preparation of Optical Films 1-1G to 1-1J)
[0333] Optical films 1-1G to 1-1J were each prepared in the same
manner as in the optical film 1-1A, except for using the coating
solutions G to J for optical functional layer, respectively as the
coating solution for optical functional layer. A slice of each of
the formed films was observed by TEM. As a result, in 1-1H, though
the high refractive index layer was formed, the hollow silica fine
particle was uniformly distributed within the low refractive index
layer and was not arranged in a line on the surface. Also, in 1-1J,
the zirconia fine particle and the hollow silica fine particle were
mixed in the optical functional layer.
(Preparation of Optical Film 1-1M)
[0334] An optical film 1-1M was prepared in the same manner as in
the optical film 1-1A, except for using the coating solution B for
middle refractive index as the coating solution for middle
refractive index. A slice of the formed film was observed by TEM.
As a result, even in 1-1M, the hollow silica fine particle was
arranged in a line on the surface, and the zirconia fine particle
was maldistributed in a lower part. Also, in 1-1M, the attachment
of contaminations or dusts was explicitly small as compared with
1-1A.
(Preparation of Optical Film 1-1KL)
[0335] Optical film 1-1KL was prepared in the same manner as in the
optical film 1-1D, except for using the coating solution K for
optical functional layer and the coating solution L for optical
functional layer in place of the coating solution D for optical
functional layer as the coating solution for optical functional
layer and using the coater disclosed in FIG. 6(A) of
JP-A-2007-293313 to send the coating solution L from a slot die and
send the coating solution K from a slide-type coating head. A slice
of the formed film was observed by TEM. As a result, even in 1-1KL,
the hollow silica fine particle was arranged in a line on the
surface, and the zirconia fine particle was maldistributed in a
lower part. Compared with 1-1D, the arrangement of the silica fine
particle and the interface planarity of the zirconia fine particle
layer in the opposite side to the support became more even.
Furthermore, approximately equivalent properties to 1-1D were shown
in integrated reflectance and scratch resistance by steel wool.
(Calculation of Surface Free Energy)
[0336] A mixture of a perfluoroolefin copolymer (P1) and reactive
silicone X-22-164B, a heat crosslinking fluorine-containing polymer
(JTA113, solids concentration: 6%, manufactured by JSR Corporation)
and a mixture of dipentaerythritol pentaacrylate and
dipentaerythritol hexaacrylate (DPHA, manufactured by Nippon Kayaku
Co., Ltd.) were each dissolved in MEK; and each of the solutions
was coated, dried and cured to prepare a cured material, surface
free energy of which was then determined alone. As to the
perfluoroolefin copolymer (P1) and the mixture of dipentaerythritol
pentaacrylate and dipentaerythritol hexaacrylate (DPHA,
manufactured by Nippon Kayaku Co., Ltd.), a photopolymerization
initiator having a solids concentration of 5% (IRGACURE 907 (trade
name), manufactured by Ciba Japan K.K.) was added. The drying and
curing condition was the same as that at the time of curing the
optical functional layer of the optical film 1-1A. The surface free
energy was calculated from a contact angle against water and
methylene iodide.
[0337] The mixture of a perfluoroolefin copolymer (P1) and reactive
silicone X-22-164B and the mixture of dipentaerythritol
pentaacrylate and dipentaerythritol hexaacrylate (DPHA,
manufactured by Nippon Kayaku Co., Ltd.) had surface free energy of
22.5 mN/m and 49.0 mN/m, respectively.
[0338] As to the silica dispersion A and dispersion B, the particle
was sedimented by means of centrifugation; after decantation, an
MEK solvent was added; and ultrasonic waves were applied for 2
minutes from an ultrasonic generator. Thereafter, the
centrifugation, the decantation, the addition of an MEK solvent and
the ultrasonic waves application were repeated 4 times; and
thereafter, the resulting mixture was cast on a glass substrate and
dried, thereby obtaining a thin film sample of oxide fine particle.
The surface free energy was calculated by means of measurement of a
contact angle of the sample. As a result, the thin film of oxide
fine particle prepared from each of the silica dispersion A and
dispersion B had surface free energy of 35.8 mN/m and 27.0 mN/m,
respectively.
(Evaluation of Optical Film)
[0339] The obtained optical films were evaluated with respect to
the following items. The results obtained are summarized in Table
1.
(1) Integrated Reflectance:
[0340] The back surface of the optical film (a surface not having
an optical functional layer) was roughed by sand paper and then
treated with a black ink, thereby making the back surface free from
reflection. In this state, an integrated reflectance was measured
by a spectrophotometer V-550 (manufactured by JASCO Corporation),
and an average reflectance at from 450 to 650 nm was calculated,
thereby evaluating antireflection properties.
(2) Evaluation of Scratch Resistance by Steel Wool:
[0341] By carrying out a rubbing test under the following condition
using a rubbing tester, it is possible to provide an index for
scratch resistance. [0342] Evaluation circumstance condition:
25.degree. C., 60% RH [0343] Rubbing material: Steel wool
(manufactured by Nippon Steel Wool Co., Ltd., Grade No. 0000). The
steel wool is wound around a tip part (1 cm.times.1 cm) of the
tester coming into contact with a sample and fixed by a band.
[0344] Movement distance (one way): 13 cm [0345] Rubbing rate: 13
cm/sec [0346] Load: 200 g/cm.sup.2 [0347] Contact area of tip part:
1 cm.times.1 cm [0348] Number of rubbing: 10 reciprocations
[0349] An oily black ink was applied on the back side of the rubbed
sample, a scratch of the rubbed portion was visually observed by
reflected light, and determination was carried out according to the
following criteria.
[0350] A: The scratch is not substantially observed.
[0351] B: The scratch is not substantially noticeable.
[0352] C: The scratch is noticeable.
TABLE-US-00002 TABLE 1 Content of Content hollow of Scratch Surface
maldistribution Sample silica in zirconia Integrated resistance by
properties of silica fine Name solid in solid Remark
P.sub.Lu/P.sub.Lt P.sub.Hd/P.sub.Ht reflectance steel wool particle
1-1A 13% 38% Appropriate 316% 186% 0.30% A Arranged in a line on
the Invention amount of silica surface 1-1B 15% 38% Appropriate
288% 186% 0.41% A Arranged in a line on the Invention amount of
silica surface 1-1C 22% 38% Large amount of 196% 186% 1.4% A
Arranged in a line on the Comparison silica surface and existed in
a lower part 1-1D 5% 38% Appropriate 320% 186% 0.52% A Arranged in
a line on the Invention amount of silica surface 1-1E 2% 38% Small
amount of 325% 186% 0.80% B Arranged in a line on the Invention
silica surface 1-1F 0% 38% No silica -- 186% 1.2% C (Zirconia
particle Comparison maldistributed in a lower part) 1-1G 13% 38%
Non-surface 5% 151% 4.8% C Mixed with zirconia particle Comparison
modified silica and also existed in a lower part 1-1H 13% 38%
Fluorine based 217% 186% 0.35% C Uniformly distributed in low
Comparison surface refractive index layer modification 1-1I 13% 0%
No zirconia 316% -- 3.0% B Mixed with zirconia particle Comparison
and also existed in a lower part 1-1J 13% 38% No 100% 100% 2.7% A
Uniformly distributed Comparison fluorine-containing together with
silica.cndot.zirconia compound particle in optical functional
layer
[0353] All of optical films 1-1A, 1-1B and 1-1D had an integrated
reflectance of not more than 1.0% and exhibited satisfactory
antireflection properties. In particular, 1-1A exhibited the most
excellent antireflection properties as 0.30%. Also, all of them
exhibited satisfactory scratch resistance. Furthermore, both of
1-1M and 1-KL had an integrated reflectance of 0.30% and exhibited
excellent antireflection properties equal to those in 1-1A. Also,
1-1M and 1-KL were excellent in the scratch resistance.
[0354] On the other hand, though the optical film 1-1E exhibited
satisfactory antireflection properties, too, it was inferior in the
scratch resistance to 1-1A. Though the optical film 1-1C
(comparative example) had satisfactory scratch resistance, it was
not sufficient in the antireflection properties; and the optical
film 1-1F (comparative example) had a high reflectance and was not
excellent in the scratch resistance. 1-1G (comparative example) had
a higher reflectance. Though 1-1H (comparative example) was
satisfactory in the reflectance, it was not excellent in the
scratch resistance; and all of 1-1I (comparative example) and 1-1J
(comparative example) exhibited a high reflectance.
[0355] A TEM photograph of a slice of each of 1-1A to 1-1J, 1-1M
and 1-1KL was taken, thereby confirming the existing state of the
hollow silica fine particle and the zirconia fine particle. In 1-1A
to 1-1C, 1-1M and 1-1KL, a state in which the zirconia fine
particle was maldistributed in a lower part, the hollow silica fine
particle was densely arranged in parallel in one layer
substantially closely on the surface, and a portion wherein the
hollow silica fine particle existed, a portion where no fine
particle existed and a portion where the zirconia fine particle
existed were distinctly separated from each other was confirmed. In
particular, in 1-1B and 1-1C, several hollow silica fine particles
superimposed and existed on the surface; and furthermore, in 1-1C,
not only the hollow silica fine particle was arranged in parallel
on the surface, but it was mixed with the zirconia fine particle
and existed in a lower part. Also, in 1-1D and 1-1E, though the
hollow silica fine particle was arranged in parallel on the
surface, it was sparsely distributed, and a site where no fine
particle existed on the outermost surface was found. In 1-1G, the
hollow silica fine particle was mixed with the zirconia fine
particle and existed only in a lower part, and a fine particle to
be maldistributed on the surface was not observed. In 1-1H, a state
in which the zirconia fine particle was maldistributed in a lower
part, and the hollow silica fine particle was uniformly distributed
in the low refractive index layer was found. In 1-1J, it was
confirmed that the hollow silica fine particle and the zirconia
fine particle were mixed and uniformly distributed over the whole
of the optical functional layer.
(Preparation of Optical Film 1-1N)
[0356] An optical film 1-1N was prepared in the same manner as in
1-1A, except that by using a die coater for simultaneous multilayer
coating (the coater as shown in FIG. 6(A) of JP-A-2007-293313), the
coating solution A for hard coat layer and the coating solution A
for middle refractive index were simultaneously extruded from a
slot part and a slide part, respectively onto the transparent
support by a slot die. As to the drying and curing condition of
each of the hard coat layer and the middle refractive index layer
having been subjected to simultaneous multilayer coating, drying
was carried out at 100.degree. C. for 2 minutes; and subsequently,
ultraviolet rays were irradiated while purging with nitrogen at 200
mJ/cm.sup.2 under a condition in an oxygen concentration of 0.1%.
Though the obtained optical film 1-1N had an integrated reflectance
of 0.4%, a value of which was slightly inferior to that of 1-1A, an
optical film having a satisfactory antireflection performance could
be efficiently prepared. Also, since it was noted that by obtaining
such antireflection ability, an antireflection structure was
formed, it could be confirmed that the low refractive index layer,
the high refractive index layer and the middle refractive index
layer were optically separated into a layer, respectively.
Furthermore, a TEM photograph of a slice was taken, thereby
confirming the existing state of the hollow silica fine particle
and the zirconia fine particle. As a result, it was found that the
zirconia fine particle was maldistributed in a lower part, thereby
forming a uniform layer and that the hollow silica fine particle
was maldistributed on the outermost surface. Also, the scratch
resistance was excellent similar to that of the optical film
1-1A.
(Preparation of Optical Film 1-1O)
[0357] An optical film 1-1O was prepared in the same manner as in
1-1A, except that by using a die coater having one more slide part
than a die coater for simultaneous multilayer coating (the coater
as shown in FIG. 6(A) of JP-A-2007-293313), the coating solution
for hard coat layer was extruded from a slot part, and the coating
solution A for middle refractive index and the coating solution A
for optical functional layer were extruded from two slide parts,
respectively and simultaneously coated onto the transparent support
by a slot die. As to the drying and curing condition of each of the
hard coat layer and the middle refractive index layer having been
subjected to simultaneous multilayer coating, drying was carried
out at 100.degree. C. for 2 minutes; and subsequently, ultraviolet
rays were irradiated while purging with nitrogen at 500 mJ/cm.sup.2
under a condition in an oxygen concentration of 0.05%. Though the
obtained optical film 1-1O had an integrated reflectance of 0.5%, a
value of which was slightly inferior to that of 1-1A, an optical
film exhibiting a satisfactory antireflection performance could be
efficiently prepared. Also, since it was noted that by obtaining
such antireflection ability, an antireflection structure was
formed, it could be confirmed that the low refractive index layer,
the high refractive index layer and the middle refractive index
layer were optically separated into a layer, respectively.
Furthermore, a TEM photograph of a slice was taken, thereby
confirming the existing state of the hollow silica fine particle
and the zirconia fine particle. As a result, it was found that the
zirconia fine particle was maldistributed in a lower part and that
the hollow silica fine particle was maldistributed on the outermost
surface. The scratch resistance of 1-1O was excellent similar to
that of the optical film 1-1A.
(Saponification Treatment of Optical Film)
[0358] Each of the foregoing optical films 1-1A, 1-1B and 1-1D was
subjected to the following treatment. That is, a 1.5 moles/L sodium
hydroxide aqueous solution was prepared and kept at 55.degree. C. A
0.01 moles/L dilute sulfuric acid aqueous solution was prepared and
kept at 35.degree. C. The prepared optical film was dipped in the
foregoing sodium hydroxide aqueous solution for 2 hours and then
dipped in water, thereby thoroughly washing away the sodium
hydroxide aqueous solution. Subsequently, the resulting sample was
dipped in the foregoing dilute sulfuric acid aqueous solution for
one minute and then dipped in water, thereby thoroughly washing
away the dilute sulfuric acid aqueous solution. Finally, the sample
was thoroughly dried at 120.degree. C.
[0359] There was thus prepared a saponified optical film.
(Preparation of Polarizing Plate)
[0360] A triacetyl cellulose film having a thickness of 80 .mu.m
(TAC-TA80U, manufactured by FUJIFILM Corporation) which had been
dipped in a 1.5 moles/L NaOH aqueous solution at 55.degree. C. for
2 minutes, neutralized and then washed with water and the
saponified optical film (each of the saponified samples 1-1A, 1-1B
and 1-1D) were adhered for protection onto the both surfaces of a
polarizer prepared by adsorbing iodine onto polyvinyl alcohol and
stretching, thereby preparing a polarizing plate. The thus prepared
polarizing plate samples are designated as polarizing plate samples
1-2A, 1-2B and 1-2D.
[0361] Also, a polarizing plate was prepared using the foregoing
saponified triacetyl cellulose film as a protective film on the
both surfaces. The thus prepared polarizing plate is designated as
a sample 1-2M (comparison).
(Evaluation of Polarizing Plate)
[0362] Each of the prepared polarizing plate samples 1-2A, 1-2B,
1-2D and 1-2M was stuck in place of a polarizing plate on the
viewing side of a liquid crystal television set ("LC-37GD4" (MVA
mode), manufactured by Sharp Corporation).
[0363] In the case of using each of the polarizing plate samples of
the examples of the invention 1-2A, 1-2B and 1-2D as a polarizing
plate, an image which is less in reflection and good in contrast
was obtained. Also, an image which is free from color tinting by
reflection on the surface and in which a black color is viewed
black was obtained. In the case of using the comparative sample
1-2M, antireflection properties were not revealed, and a strong
reflection image was reflected, thereby adversely affecting the
display performance.
(Preparation of Circular Polarizing Plate)
[0364] A .lamda./4 plate was stuck onto the surface of the optical
film 1-1A on the opposite side to the optical functional layer with
an adhesive, thereby preparing a circular polarizing plate (sample
1-3A). The sample 1-3A was stuck onto the surface of an organic EL
display with an adhesive such that the optical functional layer was
located outside. As a result, a satisfactory display performance
which is less in reflection was obtained.
[0365] The sample 1-3A was used as a polarizing plate on the
surface of each of a reflection type liquid crystal display and a
semi-transmission type liquid crystal display such that the low
refractive index layer was located outside. As a result, a
satisfactory display performance which is less in reflection was
obtained.
Example 2
Preparation of Optical Film
(Preparation of Optical Films 2-1A, 2-1B and 2-1D)
[0366] Optical films 2-1A, 2-1B and 2-1D were each prepared in the
same manner as in the optical film 1-1A, except for using the
coating solution B for hard coat layer as the coating solution for
hard coat layer and using the coating solutions A, B and D for
optical functional layer, respectively as the coating solution for
optical functional layer.
[0367] In 2-1A, 2-1B and 2-1D each using the coating solution B for
hard coat layer to which a crosslinked poly(acryl-styrene) particle
having an average particle size of 3.5 .mu.m had been added,
satisfactory antireflection properties and scratch resistance were
found, and the antireflection properties were more improved than
those in 1-1A, 1-1B and 1-1D due to the antiglare function. In
particular, the integrated reflection of 2-1A was low as 0.30% so
that excellent antireflection properties were exhibited together
with the antiglare properties.
(Saponification Treatment of Optical Film and Preparation of
Polarizing Plate)
[0368] A saponification treatment and polarizing plate preparation
were carried out in the same manners as in 1-1A, 1-1B and 1-1D,
except for using each of 2-1A, 2-1B and 2-1D as the optical film
samples, thereby preparing polarizing plate samples 2-2A, 2-2B and
2-2D.
(Evaluation of Polarizing Plate)
[0369] In the case of using each of the polarizing plate samples of
the examples of the invention 2-2A, 2-2B and 2-2D as a polarizing
plate, an image which is more improved in reflection due to
antiglare properties and good in contrast was obtained. Also, an
image which is free from color tinting by reflection on the surface
and in which a black color is viewed black was obtained. In
particular, 2-2A was substantially free from the reflection and
exhibited the most excellent antireflection properties.
Example 3
Preparation of Optical Film
[0370] (Preparation of optical films 3-1A, 3-1B and 3-1D)
[0371] Optical films 3-1A, 3-1B and 3-1D were each prepared in the
same manner as in the optical film 1-1A, except for not using the
middle refractive index layer and using the coating solutions A, B
and D for each of optical functional layers as the coating
solutions for each of optical functional layers, respectively.
[0372] Even in the case of not providing the middle refractive
index layer on the hard coat layer, in 3-1A, 3-1B and 3-1D,
satisfactory antireflection properties and scratch resistance were
found. 3-1A had a low reflection as 0.50% and exhibited excellent
antireflection properties even in a two-layer type optical
film.
(Saponification Treatment of Optical Film and Preparation of
Polarizing Plate)
[0373] A saponification treatment and polarizing plate preparation
were carried out in the same manners as in 1-2A, except for using
each of 3-1A, 3-1B and 3-1D as the optical film sample, thereby
preparing polarizing plate samples 3-2A, 3-2B and 3-2D.
(Evaluation of Polarizing Plate)
[0374] In the case of using each of the polarizing plate samples of
the examples of the invention 3-2A, 3-2B and 3-2D as a polarizing
plate, an image which is less in reflection of external light, less
in reflection and good in contrast was obtained.
[0375] The optical film of the invention is low in reflectance and
excellent in scratch resistance. Also, the method for producing an
optical film of the invention is suitable for mass production.
Furthermore, the image display device provided with the polarizing
plate using the optical film of the invention is less in reflection
of external light or reflection of background, high in visibility
and excellent in scratch resistance.
[0376] The entire disclosure of each and every foreign patent
application from which the benefit of foreign priority has been
claimed in the present application is incorporated herein by
reference, as if fully set forth.
* * * * *