Optical film and method of making said film, anti-glare polariser and display device

FIELD: physics.

SUBSTANCE: optical film has a base with convex structural components which are two-dimensionally and orderly formed directly on its surface, and a solid coating layer on the surface of the base, having said structural components. The surface of the solid coating layer has a continuous wavelike shape which matches the shape of structural components of the surface of the base. The maximum amplitude (A) and minimum wavelength (λ) of the continuous wavelike surface are essentially constant, and the ratio (A/λ) of the maximum amplitude (A) to the minimum wavelength (λ) is greater than 0.002 but not greater than 0.011. The film has full light transmission factor of 92% or higher, dullness of 1.5% or less, internal dullness of 0.5% or less and opacity of 0.7% or less.

EFFECT: improved anti-glare properties and contrast.

18 cl, 22 dwg

 

The technical field to which the invention relates.

The present invention relates to an optical film and method of its manufacture, antiglare polarizer and the display device. More specifically, it relates to an optical film provided with a hard coating layer.

The level of technology

Recently widely used variety of display devices such as liquid crystal displays (LCD display) and plasma display panel (PDP panel). The clarity of images on the screens of these display devices is greatly diminished, especially in brightly lit places, the reflection of external light such as sunlight or interior lighting. Accordingly, the commonly used optical film such as an antireflection film that create diffuse reflection of an external light on the surface of the screen.

Up to the present time in such optical films for the diffuse reflection of external light on the surface of the screen technology was used in which the surface formed of fine concave-convex structure. In particular, in current liquid crystal display devices were mostly used application method on a transparent plastic base diffusion layer in which the transparent fine particles Russ is Yana in covering the material of the coating with regard to properties abrasion.

However, in the above-mentioned various display devices, a typical representative of which are modern television receivers, flat-screen TV, improvement of image quality and sharpness quickly progressed, and the pixel size is decreased. Therefore, the light that passes through the optical film is distorted by refraction or scattering caused by small particles in the antiglare layer or the surface concave-convex structure, resulting in the problems that the image is fuzzy, there are reflections due to changes in brightness, and the surface gives a brown image, thus significantly impairing the quality. Accordingly, the existing optical film having a surface concave-convex structure formed with the fine particles are not able to follow the above improve image quality and increase of its definition. Thus, it was necessary to create an optical film having a surface concave-convex structure is formed without the use of small particles.

Meanwhile, up to the present time as a technology for forming a fine concave-convex surface structure for the diffuse reflection of external light on what arnosti screen, studied technology for forming a fine concave-convex structure by embossing (transfer forms), which are described in the publication of Japanese patent application No. 4-59605, Japanese patent No. 3374299 and in the publications of Japanese patent applications No. 2004-29240 and 2005-156615.

In the publication of Japanese patent application No. 4-59605 proposes a method for manufacturing has a high resolution non-reflective polarizing plate, comprising forming a fine concave-convex roughened surface protective film of a polarizing plate comprising the cellulose plastics, by means of a stamping process, and the subsequent dissolution of part of the surface layer of the fine concave-convex roughened surface with an organic solvent.

In Japanese patent No. 3374299 proposes a method for manufacturing the antiglare film comprising a transparent plastic film, a rough concave-convex layer consisting of resin, curable under the action of ionizing radiation, and created this plastic film, and the fine concavity and convexity located on the surface of this rough concave-convex layer, and rough concavity and convexity formed by any method from among: method of embossing method of sandblasting and how convection in the resin at the time of drying, while the fine concavity and convexity is formed from a layer thin-film coating or using the effect of expansion.

In the publication of Japanese patent application No. 2004-29240 proposes a method for manufacturing the antiglare antireflective film includes forming the concavity and convexity on the surface of the film by means of a stamping process, while the arithmetic mean deviation of the profile of the concavity and convexity of the stamp used in the stamping process, supported by 0.05 or more but not more than 2,00 μm, and the average location of the concavity and convexity supported 50 μm or less.

In the publication of Japanese patent application No. 2005-156615 proposes a method of manufacturing the antireflection film, in which at the stage of formation of a film of thermoplastic resin before or after the surface by pushing the forms in the surface film formed concavity and convexity, the film is stretched by tentering frame, and the resulting concave-convex surface is formed by a layer of hard coating.

Disclosure of inventions

Technical task

As described above, according to the publication of Japanese patent application No. 4-59605, on the surface of cellulose plastics, used as a protective film of a polarizing plate is formed by a process of stamping the fine concave-convex roughened surface, and this fine concave-convex roughened surface partially dissolved with an organic solvent, forming a smooth concave-convex surface, creating thus has a high resolution non-reflective polarizing plate. However, since the surface does not provide a hard coating layer, the polarizing plate has poor abrasion resistance. Accordingly, it is difficult to use this polarizing plate in products with LCD displays, such as LCD TVs, which require wear resistance. In addition, in the publication of Japanese patent application No. 4 - 59605 says nothing about the surface profile, which shows antireflection property.

In Japanese patent No. 3374299 and in the publication of Japanese patent application No. 2004-29240 surface profile defined by surface roughness, but the arithmetic mean deviation of the profile statistically includes large and small complex concavity and convexity. Consequently, the diffuse reflection is not regulated at all, and the resulting antireflection film becomes brown, resulting in the problem due to the significant deterioration of the picture quality.

In the publication of Japanese patent application No. 2005-156615 offered antireflection plait the ka, manufactured by transferring the concave-convex shape on a surface of a film of thermoplastic resin extrusion shape at the stage of formation of a film of thermoplastic resin, and forming a hard coating layer on the film surface by the coating. However, as the surface profile, the arithmetic mean deviation Ra of the profile of the concave-convex surface of thermoplastic resin is limited to the range from 0.05 to 10 μm (see, for example, clause 11 of the claims), and is not described any profile that shows antireflection property. Accordingly, the property of the diffuse reflection is not regulated, and the resulting antireflection film becomes brown, resulting in significant deterioration of image quality.

As described above, in conventional optical films, in which the antireflection property arises due to the surface profile without using fine particles, just modify the surface to obtain a concave-convex shape, the surface profile is determined by the surface roughness (arithmetic mean deviation (Ra) of the profile), or the surface profile is determined simply through the property of the diffuse reflection (optical property). Thus, a specific surface profile is not defined.

The meet is but the present invention is to provide an optical film and method of its manufacture, antiglare polarizer and the display device, in which a high antireflection property and high contrast can be achieved without the use of small particles.

Technical solution

The present invention is made as a result of extensive studies to solve the above problems of the prior art. The invention is described below.

The authors of the present invention conducted extensive researches and experiments to obtain the antireflection optical film, which can eliminate the feeling of opacity, while maintaining the antireflection property, and which does not contain fine particles.

The first was conducted extensive research and experiments in order to determine whether it is possible to generate the required structural components, each of which has a hemispherical or similar form, performing the transfer (forms) by squeezing roller using tinylogo roller whose surface is made of laser engraving. In the result it was found that adjusting the temperature and pressure on tinyline the shaft, you can do the transfer, to form the structural components, each the second of which has a hemispherical or similar form.

Temperature transfer and pressure transfer shall be determined in accordance with physical parameters of the transparent substrate. For example, when a transparent framework used triacetylcellulose temperature transfer is preferably in the range from 170°C to 190°C. the Reason for this is as follows. If the temperature of the transfer is lower than 170°C, the amount of the transfer is insufficient, and is formed flat plot. If the temperature of the transfer exceeds 190°C, it is easy to heat formed folds. Preferably the pressure transfer is 150 kg/cm or more. The reason for this is as follows. When the pressure of migration is lower than this may be formed flat plot, unless the transfer rate will not be reduced to a few meters per minute or less. Therefore, the processing speed is not increased and thus the productivity is low.

In addition, I found that to provide a continuous, smooth, undulating surface that approximates the shape of the structural components, foundations, obtained as a result of the transfer surface, apply the substance a solid cover, perform the drying and curing substances solid cover and regulate the thickness of the coating of the solid substances of the coating, this is basically the ideal property is on the diffuse reflection.

Preferably the coating thickness is in the range from 3 μm to 20 μm. The reason for this is as follows. If the thickness is less than 3 μm, the hardness is low, and the resulting surface is easy to scratch. If the thickness exceeds 20 μm, it increases the distortion, and this distortion tends to remain even after the basis is formed on the polarizing plate.

The present invention is made based on the above research.

To solve the above problems, the first invention provides an optical film containing:

the base containing the convex structural components, which are two-dimensional and orderly arranged on its surface; and

the layer of hard coatings on the substrate surface, and on the surface with the specified structural components

the surface of the hard coating layer has a continuous wave shape, such that approximately matches the shape of the structural components of the substrate surface,

the maximum amplitude and the minimum length λ of the wave continuous wavy surface are essentially constant, and

ratio (A/λ) of the maximum amplitude And the minimum length λ of a wave more than 0,002, but not more than 0,011.

The second invention provides a method of manufacturing the opt is a political film, containing phases in which:

forming on the substrate surface a two-dimensional ordered convex structural components; and

form on the surface with the specified structural components of the hard coating layer by coating on the surface of the base substance solid coating and curing substances solid cover,

in this case, the surface layer of hard coating to form a continuous undulating surface, so that it approximately corresponds to the shape of the structural components of the substrate surface,

the maximum amplitude and the minimum length λ of the wave continuous undulating surface is essentially constant, and

ratio (A/λ) of the maximum amplitude And the minimum length λ of a wave more than 0,002, but not more than 0,011.

The third invention provides antiglare polarizer containing

the polarizer; and

optical film provided on the polarizer,

when this optical film contains:

basis with the convex structural components, which are two-dimensional ordered on its surface; and

the layer of hard coatings on the substrate surface containing the specified structural components

moreover, the surface of the hard coating layer has a continuous wave shape, such that approximately matches the shape of p is ktorych components of the substrate surface,

the maximum amplitude and the minimum length λ of the wave continuous wavy surface are essentially constant, and

ratio (A/λ) of the maximum amplitude And the minimum length λ of a wave more than 0,002, but not more than 0,011.

The fourth invention provides a display device that contains:

a display unit for displaying the image; and

the optical film on the side surface of the display unit display,

when this optical film contains:

basis with the convex structural components, which are two-dimensional ordered on its surface; and

the layer of hard coatings on the substrate surface containing the specified structural components

moreover, the surface of the hard coating layer has a continuous wave shape, such that approximately matches the shape of the structural components of the substrate surface,

the maximum amplitude and the minimum length λ of the wave continuous wavy surface are essentially constant, and

ratio (A/λ) of the maximum amplitude And the minimum length λ of a wave more than 0,002, but not more than 0,011.

In the present invention on the surface of the hard coating layer has a continuous wave shape which approximately conforms to the shape of the structural component is in the substrate surface, moreover, the maximum amplitude and the minimum length λ of the wave continuous wavy surface are essentially constant, and the ratio (A/λ) of the maximum amplitude And the minimum length λ of the wave is in the range from 0.002 up to 0.011. Thus, on the surface of the hard coating layer is formed of a smooth wave, and light can dissipate this wave. In addition, since the hard coating layer does not contain fine particles, optical transparency can be improved compared with the traditional optical films, in which the antireflection property arises due to the fine particles protruding from the surface, and thus can be achieved with high contrast.

The technical result

As mentioned above, in accordance with the present invention, light can be scattered smooth wave on the surface of the hard coating layer and the hard coating layer has a high optical transparency. Accordingly, there can be realized an optical film having a high antireflection property and high contrast.

Brief description of drawings

Figure 1 - schematic view in section, showing one example of the construction of the liquid crystal display device according to the first variant of realization of the present invention.

Figure 2 - nematicheskii view in section, showing one structure example of the optical film in accordance with the first variant of realization of the present invention.

Figa is a top view showing an example of the concave-convex shape of the substrate material, figw - type section made according to line-In, Foundation, shown in figa, and figs - type section made according to line C-C, Foundation, shown in figa.

4 is a schematic view showing an example of the structure of the device transfer stamping, used in the method for manufacturing the optical film according to the first variant of realization of the present invention.

Figa is a top view showing one example of a concave-convex shape tinylogo roller, figw - type section made according to line-In, tinylogo roller shown in figa, and figs - type section made according to line C-C, tinylogo roller shown in figa.

Figa-6S - types related to the technological process, showing an example of a method of manufacturing the optical film according to the first variant of realization of the present invention.

7 is a schematic view in section, showing one example of the construction of the liquid crystal display device in accordance with a second embodiment implementing the present invention.

Fig is a schematic view in section, showing one of premerchantable liquid crystal display device in accordance with a third variant of realization of the present invention.

Figa-9C is a diagram showing the profile in the cross section of the optical films of Example 3, Comparative example 2 and Comparative example 3.

Figure 10 is a photograph with embossment tinylogo roller.

11 is a photograph with the embossment of the optical film of Example 1.

Fig is a graph showing the properties of the diffuse reflection from Example 3, Comparative example 1 and Comparative example 3.

Fig is a graph showing the relationship between the ratio of maximum amplitude And/minimum length λ of the wave" and opacity.

Fig is a graph showing the relationship between coating thickness and anti-reflection property.

The best ways of carrying out the invention

Next, with reference to the drawings will be described the embodiments of the present invention. Note that in all the drawings illustrating the embodiments of the invention described below, the same or corresponding components are assigned the same reference position.

(1) the First implementation of the invention

(1-1) Construction of liquid crystal display devices

Figure 1 shows one example of the construction of the liquid crystal display device according to the first variant of realization of the present invention. As shown in figure 1, the liquid crystal device so the Oia includes the backlight (3), which emits light and a liquid crystal panel (2), which provides temporal and spatial modulation of the light emitted by the backlight (3), to display the image. On two surfaces of the liquid crystal panel (2) are provided respectively polarizers (2A) and (2b). On the polarizer (2b)provided on the side surface of the liquid crystal display panel (2), provided antiglare film (1). In the present invention, the polarizer (2b), having on one main surface of the antiglare film (1), referred to as antiglare polarizer (4).

For example, as a backlight (3) can be used, the backlight of the direct type, the backlight edge type or the backlight related to the type planar light source. The backlight (3) includes, for example, the light source reflecting plate, optical film and the like, for Example, as a light source is used fluorescent cold cathode lamp (CCF lamp), fluorescent lamp, a hot cathode (HCFL-bulb), organic electroluminescence (OEL), light emitting diode (LED) or the like

Examples of the display method, which can be used for a liquid crystal panel (2)include a method with a twisted nematic elements (TN-way),the way superstructure nematic elements (STN-way), the way the vertical alignment (VA-fashion), fashion planar switching (IPS-method), the method of double refraction optical compensation (start method), a method of ferroelectric liquid crystals (FLC-way), the way in polymer dispersed liquid crystals (PDLC-method) and the method based on the effect of "guest - host" phase transformation (PCGH-way).

Polarizers (2A) and (2b) are provided respectively on two surfaces of the liquid crystal panel (2) so that their axes of transmission are, for example, orthogonal to each other. Each of the polarizers (2A) and (2b) allows the passage of only one of the orthogonal polarized components of the incident light and detains another component, absorbing it. Each of the polarizers (2A) and (2b) can be stretched in the direction of one axis of the hydrophilic polymer film, such as film based on polyvinyl alcohol film based on partially processed formaldehyde polyvinyl alcohol, partially saponified film based on a copolymer of ethylene and vinyl acetate or similar film with adsorbed therein a dichroic substance such as iodine or dichroic dye.

(1-2) structure of the antireflection film

Figure 2 shows one example of the structure of the optical film in accordance with the first variant of realization this is part II of the invention. As shown in figure 2, the optical film (1) includes a base (11) and a layer (12) hard cover, provided on the basis of (11).

It is preferable that the total light transmittance was 92% or more. The reason for this is that in the case of 92% or more of the light energy emitted by backlight, can be stored without deteriorating the transparency of the transparent base. Preferably, the Mat was 1.5% or less. The reason for this is that in the case of 1.5% or less, the dispersion of the light emitted by the backlight, and the dispersion of light reflected by the surface, can be eliminated, and therefore the black color is seen as black. Preferably, the internal haze of 0.5% or less. The reason for this is that in the case of 0.5% or less, the dispersion of the light emitted by the backlight, can be similarly eliminated, and colors seen as in color, more close to natural colors. Preferably, the opacity was 0.7% or less. The reason for this is that in the case of 0.7% or less in the same way, black is seen as black. Note that the opacity represents the sum of the Mat surface and internal haze.

Basis

The base (11) is a plastic base with PR is transparency. As for the shape of the base (11), can be used, for example, film, sheet or substrate having transparency. As the material for the base (11) can be used, for example, known polymeric materials. Specific examples of known polymeric materials include triacetylcellulose (TAS), polyesters (TRAY), polyethylene terephthalate (PET), polyimides (PI), polyamide (PA), aramids, polyethylene (PE), polyacrylates, polyethersulfone, polysulfone, polypropylene (PP), dietetically, polyvinyl chloride, acrylic resin (polymethyl-methacrylate (emission spectra obtained for pure)), polycarbonate (PC), epoxy resin, urethane resin and melamine resin, resin-based cycloolefins (e.g., ZEONOR), and copolymers of styrene and butadiene copolymer (SBC). From a performance perspective, it is preferable that the thickness of the base (11) ranged from 38 μm to 100 μm, but this range is not limited.

In addition, it is preferable that the base (11) had the function of a protective film of polarizer (2b). The reason for this is that the polarizer (2b) it is not necessary to separately provide another protective film, and thus the thickness of the polarizer (2b)having an optical film (1)may be reduced.

Figure 3 shows an example of a concave-convex shape of the substrate surface. As shown in figure 3, the base (11) has a concave-convex shape on one core on which ernesti, which includes a layer (12) hard cover. In particular, on the surface of the element base (11) two-dimensional and orderly manner are convex structural components (11a). Specific examples of configuration (R) location of structural components (11a) includes a rectangular, hexagonal and octagonal configuration. Note that figure 3 shows an example in which the structural components (11) are in the form of a hexagonal configuration. Preferably, the structural components (11a) had essentially the same height. If you look from the top of any of the structural components (11a), structural components (11a) orderly arranged in two different directions (a) and (b). The angle (θ)formed by the direction (a) and direction (b), properly selected according to the desired configuration (R) locations. For example, in the case in which the configuration (R) is a hexagonal configuration, as shown in figure 3, the angle (θ)formed by the direction (a) and direction (b)is 60 degrees. In addition, it is preferable that the cross section of the layer of solid coating performed on these two different directions, had a continuous wave shape.

Examples of the shape of the convex structural components (11a) include hemispheres is ical shape (dome shape), pyramid-shaped and columnar forms. However, the convex shape of the structural component (11) is not limited to these forms and can be appropriately selected in accordance with the desired optical properties. Examples of pyramidal shapes include conical, truncated cone shape and a polygonal pyramid shape. Examples of polygonal pyramidal forms include a quadrangular pyramid, a hexagonal pyramid octagonal pyramid. Examples of columnar shapes include cylindrical shape and a polygonal columnar shape. Examples of polygonal columnar shapes include rectangular column, hexagonal column and octagonal column. In addition, structural components (11a) can be attributed to the shape anisotropy. From the point of view of the configuration of the optical properties of the display device is performed in the horizontal direction and in the vertical direction, preferably, for example, from among those available in the same plane directions based on (11) the shape anisotropy was given in two orthogonal directions. Specific examples of the shape of the structural component (11 a)having a shape anisotropy, include an elliptical columnar shape, semi-elliptical spherical shape, a truncated elliptic cone shape is a polygonal columnar shape and a polygonal pyramid shape, which stretched in one direction.

As a form of interval (11b) between the structural components can be used, for example, the form of V-shaped cross-section, form a U-shaped cross-section, etc. But this form is not limited to these options, and can be suitably selected in accordance with the desired optical properties. In addition, the gap (11b) between the structural components can be attributed to the shape anisotropy. From the point of view of the configuration of the optical properties of the display device is performed in the horizontal direction and in the vertical direction, preferably, for example, from among those available in the same plane directions based on (11) the shape anisotropy was in two orthogonal directions. In particular, for example, the distance between the intervals (11b) may vary in different directions. For example, the distance between the intervals (11b) in one direction may be greater than the distance between the intervals (11b) in the other direction, and these two directions are orthogonal to each other in the plane.

The layer of hard coating

Layer (12) hard cover attaches to the substrate surface (11), that is, the surface of the optical film, display device, etc. wear resistance and antireflection property and providing yet a polymer resin, which is more rigid than the base (11). The surface layer (12) hard cover has a continuous wave shape which approximately conforms to the shape of the structural components (11a) of the base (11). The location of concave and convex portions of the layer (12) hard cover corresponds to the locations of the concave and convex areas of the base (11). Accordingly, the magnitude of concavity and convexity on the surface of the layer (12) hard cover less than the magnitude of concavity and convexity on the surface of the substrate. The greater the thickness of the coating layer (12) hard cover, the less the magnitude of concavity and convexity.

Each parameter of a number: the maximum amplitude (A) and the minimum length (λ) of a wave this continuous undulating surface is essentially constant. Accordingly, the coating layer (12) of a solid coating on the entire surface, you can eliminate the appearance of flat land, and thus may be provided with antireflection property. In addition, the ratio (A/λ) max amplitude (A) the minimum length (λ) of a wave more than 0,002 and is to 0.011 or less. The reason for this is as follows. In the case of relations constituting 0.002 or less, antireflection property tends to decrease, and in the case of relationships, exceeding 0,011, nephros agnosti tends to increase. In the present invention, the term "continuous wavy surface" means that surface of the layer of hard coating, there are no discontinuities or steps, and the surface is smoothly connected, and in particular, at any point on the surface layer (12) hard coatings can be executed differentiation. In addition, the term "minimum length (λ) of a wave" refers to the minimum distance from among the distances between vertices of adjacent structural components (11a). In addition, the term "maximum amplitude" refers to the height of the vertices of the convex section, the reference point is taken as the bottom surface of the concave surface undulations.

Preferably, the cross-section of the layer (12) hard coatings, obtained by incision, passing through the vertices adjacent structural components (11a), had a continuous wave-like form, and, in addition, it is preferable that it had a sinusoidal wave shape. The reason for this is that can be achieved with good property of the diffuse reflection. In the present invention, the term "sine wave" also includes substantially sinusoidal wave form.

(1-3) the Device transfer stamping

Next, with reference to figure 4 will be described device per the nose stamping, intended for forming the base (11)having the structure described above. As shown in figure 4, transfer device stamping includes tinily roller (21) and the reverse roller (22).

For example, as tinylogo roller (21) can be used for the heating roller, such as roller shirt induction heating roller with a circulating heat carrier or platen with the installed heater. As a method for embossing the surface of the roller, can be used in a variety of ways, such as laser engraving, sandblasting, engraving machine or photoetching, but laser engraving is preferred. The reason for this is as follows. Abrasive blasting is difficult to make the depth of the concave sections (21A) of the same and to form concave sections (21) of the two-dimensional and orderly manner. When engraving machine, fotoralerei or similar methods, it is difficult to perform etching with a high density exceeding 250 lines/inch. In addition, for engraving ultra-high density in excess of 500 lines/inch, it is preferable that the etching was performed by laser carbon dioxide or YAG laser grenade. From the point of view that was achieved with good wear-resistance with long-term use, p is impactfully as the surface treatment is a coating of hard chrome plating or spraying ceramics.

To transfer small embossment on the surface of the base must be attached to the reverse roller (22) high pressure. Therefore, it is preferable that the reverse roller (22) include, for example, a rubber layer having a hardness rubber component 80 units on Japanese industrial standard JIS-D or more, or a resin having a hardness corresponding to that hardness rubber layer or a resin layer provided on the surface of the steel roller, and it is preferable that the surface of the rubber layer or a resin layer was processed completely by polishing.

In addition, it is preferable that the cooling was carried out by circulating the cooling medium in the steel roller reverse roller (21), or the surface of the rubber layer or a resin layer is cooled using a cooling roller or the cooling nozzle. The reason for this lies in the fact that it was possible to prevent the phenomenon in which the temperature of the rubber layer or a resin layer opposite the roller (22) increases due to the gradual migration of heat from tinylogo roller (21) during the stamping process, which results in the softening or melting of the base (11), and to perform subsequent transfer stamping.

Figure 5 is one example of concave-convex form tinil the CSOs roller. As shown in figure 5, tinily roller (21) has a cylindrical surface of the concave-convex shape (embossment). In particular, on the surface tinylogo roller (21) provide for the concave sections (21A) to form on the basis of (11) structural components (11a). Concave sections (21A) are disposed on the surface tinylogo roller (21) two-dimensional and orderly manner. Specific examples of configuration (B) concave (21A) include rectangular, hexagonal and octagonal configuration. Note that figure 5 shows an example in which the structural components (11) are arranged in a hexagonal configuration. In addition, when viewed from the top of any of the structural components (11a), structural components (11a) orderly arranged in two different directions (a) and (b). The angle (θ)formed by the direction (a) and direction (b), properly selected according to the desired configuration (R). For example, if the configuration (R) is hexagonal, as shown in figure 5, the angle (θ)formed by the direction (a) and direction (b)is 60 degrees.

Examples of the shape of the concave sections (21A), forming structural components (11a), include a hemispherical shape (dome shape), a pyramidal shape and a columnar shape. However, the concave shape in which Astrov (21A) is not limited to these forms and can be appropriately selected in accordance with the desired optical properties. Examples of pyramidal shapes include conical, truncated cone shape and a polygonal pyramid shape. Examples of polygonal pyramidal forms include a quadrangular pyramid, a hexagonal pyramid octagonal pyramid. Examples of columnar shapes include cylindrical shape and a polygonal columnar shape. Examples of polygonal columnar shapes include rectangular column, hexagonal column and octagonal column. In addition, concave portions (21A) can be attributed to the shape anisotropy. From the point of view of the configuration of the optical properties of the display device is performed in the horizontal direction and in the vertical direction, preferably, for example, from among those available in the same plane directions on tinyline roller (21) shape anisotropy was in two orthogonal directions, for example, in the circumferential direction and in the direction of height. In particular, examples of the shape of the concave sections (21A)having a shape anisotropy, include an elliptical columnar shape, semi-elliptical spherical shape, a truncated elliptical cone shape, and a polygonal columnar shape and a polygonal pyramid shape, which stretched in one direction.

As a form of interval (21b) between the concave the plots can be used for example, the form of V-shaped cross-section, form a U-shaped cross-section, etc. But this form is not limited to these options, and can be suitably selected in accordance with the desired optical properties of the optical film (1). In addition, the shape of the gap (21b) between the structural components may not require anisotropy. From the point of view of the configuration of the optical properties of the display device is performed in the horizontal direction and in the vertical direction, preferably, for example, from among those available in the same plane directions on tinyline roller (21) shape anisotropy was in two orthogonal directions, for example, in the circumferential direction and in the direction of height. In particular, for example, the distance between the intervals (21b) between the concave sections in one direction may be different in different directions. For example, the distance between the intervals (21b) between the concave sections in one direction may be greater than the distance between the intervals (21b) in the other direction, and these two directions are orthogonal to each other in the plane.

(1-4) the Method for manufacturing the optical film

Next, with reference to 6 will be described an example of a method for manufacturing the optical film having the above structure is at. Preferably, each step described below, was carried out in the process of being transferred from roller to roller in order to improve performance and reduce costs.

Stage migration

First base (11) is heated and squeeze with continuous rotation tinylogo roller (21) and the reverse roller (22) in a state in which the base (11) is located between them, using the device transfer stamping, shown in figure 4, thus transferring concave-convex shape on the surface of the base (11). Thus, as shown in figa, on the substrate surface (11) two-dimensional and orderly formed structural components (11a).

The stage of preparation of the coating material

Then mixed, for example, resin, initiator of photopolymerization and the solvent thereby to prepare the solid substance of the coating (coating material). In addition, if necessary, can be added photostabilization absorber of ultraviolet rays, antistatic agent, flame retardant product, an antioxidant and a viscosity modifier, etc.

From the standpoint of ease of manufacture it is preferable that the resin contained as a main component at least one resin from among resins, curable under the action of ionizing radiation, which otverzhdajutsja under the action of light, electron beams, etc. and those who moreactive resins, which otverzhdajutsja under the influence of heat. Most preferred are photosensitive resins which otverzhdajutsja under the action of ultraviolet rays. Examples of such a photosensitive resin which can be used include acrylate resins such as urethane acrylates, epoxy acrylates, polyester acrylates, polyol acrylates (high molecular weight alcohol), polyether acrylates and melamine acrylates. For example, urethane acrylate resin, receive, allowing the polyester polyol to interact with isocyanate monomer or a prepolymer, and then allowing the product obtained in the reaction, to interact with the containing hydroxyl group of the acrylate or methacrylate monomer. It is possible to properly adjust characteristics of the resin after curing. For example, the resin, which has good light transmittance property, is preferred from the viewpoint of transmittance images, and resin, which has high hardness, is preferred from the viewpoint of resistance to scratching. Note that this photosensitive resin is not particularly limited to the above examples, and can be used any of a photosensitive resin having a light transmittance property. However, preferred is the mole, which does not cause significant changes of the hue of the captured light and the amount of noise light due to its color and opacity. In particular, it is preferable to use a resin having a refractive index which does not differ substantially from the refractive index used in the base (11). The reason for this is that when using a resin having a refractive index substantially different from the refractive index of the base (11), is reflected on the boundary surface with the base, and the resulting basis becomes opaque.

Preferably, with photosensitive resin were appropriately mixed and used urethane resin, acrylic resin, methacrylic resin, styrene resin, melamine resin or a cellulose resin, which becomes hard when dried, in addition, oligomer, curable under the action of ionizing radiation, or thermosetting oligomer. Hardness and curl layer (12) hard coatings can be adjusted by appropriately mixing these resins. These resins are not limited to the above examples. For example, there may be used a polymer which has a functional group sensitive to the action of ionizing radiation, such as an acrylic double bond, or thermoreactive the ing group, such as the group-HE.

Examples of the photopolymerization initiator of the contained in the photosensitive resin include derivatives of benzophenone compounds, derivatives, acetophenone compounds and derivatives of the compounds of the anthraquinone. They can be used individually or in combinations. In addition, it is possible to properly choose and mix with a photosensitive resin component, which improves the formation of the coating film, such as acrylic resin, etc.

Preferred is a solvent which dissolves the material used is resin, which has good wetting ability in relation to the base (11) and which will not discolor the base (11). Examples of the solvent include solvents composed of ketones or esters of carboxylic acids, such as acetone, diethylketone, DIPROPYLENE, methyl ethyl ketone, methylethylketone, methyl isobutyl ketone, cyclohexanone, methylformate, ethyl formate, paperformat, isopropylpalmitate, bodyformat, methyl acetate, ethyl acetate, propyl, isopropylacetate, butyl acetate, isobutyl acetate, secondary butyl acetate, amylacetate, isoamylase, secondary amylacetate, methylpropionate, ethylpropane, methylbutyrate, ethyl butyrate and mutilated; and alcohols, such as methanol, ethanol, isopropanol, n-butanol, secondary butanol and three-butane is La. These solvents may be used individually or as a mixture of two or more ingredients. In addition, solvents other than the solvents listed above as an example, can be added in an amount which does not impair the characteristics of the resin composition.

As antistatic agents can for example be used with a conductive carbon, inorganic fine particles, fine powder, surfactant, ionic liquid, etc. These antistatic agents can be used individually or in combinations of two or more. Examples of materials for the inorganic fine particles and inorganic fine powder include materials containing as a main component, a conductive metal oxide. As the electrically conductive metal oxide may, for example, used a tin oxide, double oxide of indium, tin oxide mixed with antimony (ATO), tin oxide mixed with indium (ITO), zinc oxide with antimony, etc.

Examples of surfactants include anionic or amphoteric compounds, such as compounds carboxylic acids and salts of phosphoric acid; kationaktivnaya compounds such as amine compounds and salts of Quaternary ammonium bases; nonionic compounds such as compounds greasy the acid and ester of a polyhydric alcohol and a polyoxyethylene adducts of; and polymer compounds such as derivatives of compounds of polyacrylic acid. Ionic liquids are molten salts that are liquid at room temperature. Preferred are ionic liquids that are compatible with the solvent and the resin, and they are compatible with the resin even after the solvent evaporates during drying, as described below. Specific examples kationaktivnaya types of ion pairs include aliphatic cations are Quaternary ammonium compounds composed of nitrogen-containing niewyk compounds, cations are Quaternary ammonium compounds having nitrogen-containing heterocyclic structure, the cations of the phosphonium composed of phosphate niewyk salts, the cations of sulfone composed of sulfur-containing niewyk compounds. Examples of the anionic species of ion pairs include halogen anions, organic anions are carboxyl group and an organic fluorine-containing anions. In particular, it is preferable that the anion represented a fluorine-containing organic anion, such as Tris (TRIFLUORIDE methylsulphonyl) nitric acid as the anion readily forms ionic liquid pair at ordinary temperature. In addition, ionic liquids can be used individually, or several types of ion LM the bones can be used in combination with each other. Phase coating

Next, as shown figv prepared substance (13) a hard coating is applied on the basis of (11). Although the liquid level caused as a substance (13) hard coatings, is a horizontal line thickness between the liquid level and the concave-convex shape on the substrate surface is distributed and thus due to changes in volume when dried forms a smooth concave-convex surface section of gas - liquid. The result can be an optical film (1), in which the value of the concavity and convexity of the surface layer (12) hard cover less than the magnitude of concavity and convexity of the surface of the substrate (11). In addition, due to the magnitude of concavity and convexity of the surface of the substrate (11) can be adjusted diffuse reflection by changing the thickness of the applied substance (13) hard coatings. In addition, since the surface can be formed in a contactless manner when all of the process from coating to cure, there can be obtained high-quality optical film (1), devoid of defects.

Method of coating does not particularly limited and may be used any known method of coating. Examples of known methods of coating include a method of coating microg overovanim cylinder, the method of coating the wire rod, the method of directly coating the engraved cylinder, the method of applying a coating in the form, method of coating, dipping, a method of coating the coating, the method of coating, reverse roller, a method of coating irrigation, method of coating the strokes, the way of the knife coating device and method of coating by centrifuging.

Stage drying

Then the substance (13) hard coatings deposited on the base (11), is dried to evaporate the solvent. Drying conditions does not particularly limited. Drying can be a natural drying or artificial drying, which are governed by drying temperature and drying time. However, if the surface of the coating material is subjected during drying to blowing a stream of air, preferably on the surface of the coating film was not formed ripples from the air stream. The reason for this is that if formed ripples from the air flow, the surface of the antireflection layer is not likely required gentle undulating fine concave-convex shape, and thus it becomes difficult to achieve as antireflection properties, and contrast. In addition, the drying temperature and drying time mo is ut to be properly determined on the basis of the boiling point of the solvent, contained in the coating material. In this case, it is preferable that the drying temperature and drying time were installed in the ranges, in which, taking into account the heat resistance of the base (11), no deformation of the base (11), caused by thermal shrinkage.

Stage curing

Then the resin is dried on the base (11), cures, for example, by irradiation with ionizing radiation or by heating. As a result, as shown in figs, on the surface layer (12) hard coatings can be formed smooth undulating surface on which the structural component (11) forms a single peak. As ionizing radiation can be used, for example, electron beams, ultraviolet rays, visible rays, gamma rays, electron beams and Ultraviolet rays etc. are preferable from the viewpoint of production equipment. Preferably, the total dose of irradiation was chosen appropriately based on the properties of the cured resin, eliminating the yellowing of the resin and the base (11) and similar considerations. In addition to this, the atmosphere during irradiation can be appropriately selected in accordance with the state of the cured resin. Examples of the atmosphere include air and inert gas, such as nitrogen or argon.

The result is the set of protowall covoy film.

In the first variant of realization of the present invention on the surface of the hard coating layer formed of a continuous undulating surface, the shape of which approximates the shape of the structural components (11a) on the substrate surface, with each value from among the maximum amplitude (A) and the minimum length (λ) of a wave of continuous wavy surface is essentially constant and the ratio (A/λ) max amplitude (A) the minimum length (λ) of a wave is in the range from 0.002 up to 0.011. Accordingly, without using fine particles can be realized antireflection optical film, which can be eliminated the feeling of opacity while maintaining antireflection properties. In addition, the antireflection property of the optical film can be freely designed by changing concave-convex shape of the surface.

In addition, if the pressure roller is performed using tinylogo roller (21)with laser engraving formed honeycomb holes with the location of 500 lines/inch (diameter: about 50 μm) and a depth of 5-10 μm, by transfer, by adjusting the temperature and pressure on tinyline roller (21), to form a dome-shaped structural components (11a), each of which has received the transfer of the convex teaching is the current thickness of from 2 to 6 μm. In addition, the obtained transfer surface is covered with a substance (13) hard cover, and it dries and hardens, whereby along the concave-convex shape of the base (11) can be obtained surface profile having a smooth sinusoidal wave shape. At this stage, simply by adjusting the thickness of the coating can be achieved essentially the ideal property of the diffuse reflection. By performing the above process, can be formed on the surface layer of solid coating smooth wave, which is important for the realization of high antiglare property and a low opacity. In addition, the property of the diffuse reflection can be easily adjusted. In addition, the required optical film, devoid of defects, and this requirement can also be satisfied.

In addition, to set antireflection properties (properties of the diffuse reflection on the surface tinylogo roller (21) is formed concave-convex pattern with an ordered arrangement. As in the case of sandblasting, which is commonly used, concavity and convexity are formed three-dimensional, there is no other choice but to represent the surface profile in terms of arithmetical mean deviation of the profile. In addition, when a hard coating applied is by this last sandblasted surface, antireflection property can be enhanced, but has the adverse effect that small concavity and convexity on the basis of are trapped in the layer of hard coating due to viscosity and surface tension of the coating material of the coating. Accordingly, until now it was difficult to define the surface profile, which shows antireflection property. In contrast, in the first embodiment of the invention the transfer stamping is performed by using a punch with concave-convex pattern having the same depth and orderly arrangement, thus forming on the substrate surface protrusions having the same height as the thickness of the coating of the substance (13) hard cover changes. Thus, it can be determined the relationship between the ratio of amplitude (A) / length (λ) of the wave formed on the surface, and anti-reflection property (property of the diffuse reflection).

In addition, if the transfer occurs sandblasting, the magnitude of concavity and convexity of the surface tend to be unequal, and the relatively small concave-convex sections are concealed when applying a hard coating, and the surface tends to become flat. Accordingly, for the manifestation of protiva ecologo properties you want to accurately control the coating thickness. Also from the viewpoint of productivity, it is preferable that the transfer was carried out using tinylogo roller, which has the same height of the concavity - convexity.

(2) the Second implementation of the invention

Fig.7 is a view in section, showing one example of the structure of the optical film in accordance with a second embodiment implementing the present invention. As shown in Fig.7, the optical film is different from the optical film according to the first embodiment of the invention that between the base (11) and a layer (12) hard cover is provided an antistatic layer (14). Because the base (11) and a layer (12) hard coatings are the same as in the first embodiment of the invention, they are assigned the same reference position, and their description is omitted.

Antistatic layer (14) contains a resin and an antistatic agent. In accordance with the need for antistatic layer may be included photostabilization absorber of ultraviolet rays, antistatic agent, flame retardant product, an antioxidant, etc. as resin and antistatic agents may be used the same resin and an antistatic substance that is used in the layer (12) hard cover in the first embodiment of the invention.

Because the second variant of realization of izopet the deposits between the base (11) and a layer (12) hard cover is provided an antistatic layer (14), there can be obtained optical film, which shows a high antireflection property, high contrast, abrasion resistance and anti-static function.

(3) the Third variant of the invention

Fig is a view in section, showing one example of the structure of the optical film in accordance with the third variant of realization of the present invention. As shown in Fig, the optical film (1) is different from the optical film according to the first embodiment of the invention that the layer (12) hard coating provides an anti-reflective layer (15). Because the base (11) and a layer (12) hard coatings are the same as in the above described first embodiment of the invention, they are assigned the same reference position and their description is omitted.

For example, an antireflection layer (15) can be used a layer with a low refractive index, containing hollow fine particles or a layer with a low refractive index, containing fluoride resin. Examples of hollow fine particles include inorganic fine particles such as silicon dioxide and aluminum oxide, and organic fine particles such as styrene and acrylic. Particularly preferred fine particles of silicon dioxide. Because of the hollow fine particles contain inside the air, they are the motor of refraction lower than the ordinary refractive index of the fine particles. For example, while the refractive index of the fine particles of silicon dioxide is of 1.46, and the refractive index of the hollow fine particles of silica is 1.45 or less.

As in the third embodiment of the invention the layer (12) hard coating provides an anti-reflective layer (15), the antireflection property can be improved compared with the first variant implementation of the invention.

EXAMPLES

Now the present invention will be described by way of examples, but the present invention is not limited to only these examples.

In these examples, the embossment was transferred to a film that serves as the basis, the device transfer stamping shown in figure 4. Below will be described the device transfer stamping, used in the examples.

On the surface tinylogo roller has been coated ceramics of oxide of chromium. After polishing executed engraving laser carbon dioxide density engraving 500 lines/inch to form a stamp for stamping having a honeycomb of holes with an average diameter of approximately 50 μm and a depth of 10 μm. In addition, in tinyline roller was installed heater for heating so that the temperature could be maintained 00°C or higher.

Reverse roller was prepared by winding on the iron surface of the platen rubber hardness of 90 units on Japanese industrial standard JIS-D and finishing by polishing, and this was used with a cooling roller for cooling and nozzle air cooling. Film from triacetylcellulose (TAS) thickness of 80 μm was heated and squeezed with continuous rotation tinylogo roller and the reverse roller in the state in which this film from triacetylcellulose was sandwiched between them. If the embossing is carried out in conditions of low temperature and low pressure on the surface of the film along the walls of the embossment, which contacts the film, are formed simply scratches, and a dome-shaped protrusions may not be formed. In contrast, at high temperature and high pressure, although the magnitude of the transfer is great, the film is thermally deformed, and it is impossible to produce a satisfactory product. At higher line pressure, the value of the transfer increases. However, you cannot achieve a uniform linear pressure in the direction of the width, because the bending roller is increased. Accordingly, there should be made an economic decision. That is, it is important that the physical properties and dimensions of the framework were found Optima is performance communications conditions stamping.

As for the concave-convex pattern formed on the surface tinylogo roller, the examples was formed concave-convex pattern with an ordered arrangement that specifies the antireflection property (the property of the diffuse reflection). In the case of sandblasting, which is usually used, because of the concavity and convexity are formed three-dimensional, there is no other choice but to represent the surface profile in terms of arithmetical mean deviation of the profile. In addition, when a hard coating is applied to such past sandblasted surface antireflection property can be enhanced, but has the adverse effect that small concavity and convexity on the film are embedded in the layer of hard coating due to viscosity and surface tension of the solid substances of the coating. Accordingly, until now it was difficult to define the surface profile, which shows antireflection property.

In the examples, the transfer stamping was performed using a punch with concave-convex pattern having an ordered arrangement and the same depth, thus forming on the film surface structural components that have the same height. The relationship between the ratio of maximum amplitude (A) / minimum length (λ) of the wave is", formed on the surface, and anti-reflection property (property of the diffuse reflection) can be determined by changing the thickness of the layer (12) hard coating.

EXAMPLE 1

First film from triacetylcellulose (TAS) thickness of 80 μm was compressed at a linear pressure of 2000 N/cm, with continuous rotation tinylogo cushion, heated to 180°C, and the reverse roller, cooled to 50°C, in a state in which the film of triacetylcellulose sandwiched between them. Thus, the concave-convex shape tinylogo roller is continuously transferred to the surface of the film from triacetylcellulose. Then 80 parts by weight of the acrylic-urethane oligomer, 20 parts by weight of acrylic polymer, curing and drying, and 5 weight parts of an initiator of the reaction IRG-184 were mixed with butyl acetate to prepare substances solid surface. The solid substance coating was deposited on the concave-convex surface film from triacetylcellulose by means of a wire rod. At this stage, through the appropriate choice of the combination of the diameter of the wire rod and the solids content of the resin in the solid substance coating the ratio of the maximum amplitude (A) / minimum length (λ) of a wave after drying and hardening substances solid coating was maintained 0,0108. Then the solvent was evaporated in a drying oven n and 80°C. Following this, the resulting film was passed into the furnace for curing under the action of ultraviolet radiation, and curing was conducted under the action of ultraviolet rays at an output power of 160 watts and the total light energy of 300 MJ/cm2. The result was cooked specified optical film.

EXAMPLE 2

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0098.

EXAMPLE 3

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0071.

EXAMPLE 4

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0051.

EXAMPLE 5

The optical film was need a kitchen is Lena, as in Example 1, except that the combined thickness of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0027.

EXAMPLE 6

First was obtained as in Example 1, the film on which the transferred concave-convex shape. Then the tin oxide mixed with antimony (ATO), having a particle diameter of 30 nm, and urethane-acrylic oligomer, which is a resin curable by ultraviolet radiation, are mixed in a volume ratio of 1:1 to receive material dispersion coating (IPA dispersion). This material dispersion coating was applied on the film from triacetylcellulose so that the average film thickness after drying was 300 nm, and dried to form an antistatic layer. Then the film from triacetylcellulose put the substance a solid coating and utverjdayut him as in Example 1 to prepare an optical film.

EXAMPLE 7

One hundred weight parts of curing under the action of ultraviolet radiation urethane-acrylic oligomer, 5 weight parts of an initiator of the reaction IRG-184 and 40 parts by weight of fine particles of antimony pentoxide (particle diameter: 30 nm)were added to the mixed p is storytell MIBK/IPA=1/1 so to the solids content was 40%, and mixed and shaken up to get substances solid surface. An optical film was prepared as in Example 1, except that used this substance solid surface.

COMPARATIVE EXAMPLE 1

Five parts by weight of fine particles of styrene, having a diameter of 5 to 7 μm, and the average particle diameter of 6 μm, 100 parts by weight of tetrafunctional urethane-acrylic oligomer, curable under the action of ultraviolet radiation, and 5 weight parts Irgacure 184, which serves as a photochemical reaction initiator, were added to tertiary butanol, and the resulting mixture was stirred to prepare a 40%aqueous solution of butanol. Following this, the solution was filtered using a filter with a hole diameter of 50 μm to prepare the coating material. Then the filtered coating material was applied on the film from triacetylcellulose thickness of 80 μm by means of a device coating using an engraved cylinder, and the film was then dried in a drying oven, in which the drying temperature was set at 80°C. Following this, the film is continuously passed from the drying oven in the oven for curing under the action of ultraviolet radiation was irradiated with ultraviolet ray of the mi at output power of 160 watts and the total light energy of 300 MJ/cm 2, thus forming a film from triacetylcellulose antireflection film having an average film thickness after curing of 8 μm. Thus was prepared the specified optical film.

COMPARATIVE EXAMPLE 2

An optical film was prepared as in Example 1, except that was omitted the step of applying a substance hard surface.

COMPARATIVE EXAMPLE 3

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0162.

COMPARATIVE EXAMPLE 4

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0137.

COMPARATIVE EXAMPLE 5

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum is th length (λ) of the wave" was 0,0127.

COMPARATIVE EXAMPLE 6

An optical film was prepared as in Example 1 except that the combination of the diameter of the wire rod and the solids content of the resin in the solid substance of the coating was selected such that the ratio of the maximum amplitude (A) / minimum length (λ) of the wave" was 0,0020.

Were measured and evaluated in a concave-convex shape (the maximum amplitude (A) / minimum length (λ) of the wave), the property of the diffuse reflection, opacity, antireflection property, total light transmittance, haze and the internal haze of the optical films of Examples and Comparative examples prepared as described above.

Evaluation of concave-convex form.

Concave-convex shape, height difference, the amplitude and the maximum amplitude (A) / minimum length (λ) of the wave were measured using a laser microscope, produced by Lasertec Corporation (Lazetic Corporation). The results are shown in Table 1. In addition, the measured profiles from Example 3, Comparative example 2 and Comparative example 3 are shown in Fig.9 as typical examples of the profiles. In addition, photographs were taken of the embossment on tinyline platen used in the transfer stamping on the film from triacetylcellulose, and the embossment on the optical film When the EPA 1. The results are shown in figure 10 and 11 respectively.

Evaluation of the diffuse reflection

In order to eliminate the influence of the reflection on the rear surface, each optical film attached to a black acrylic plate through in between sticky substance, bounding with pressure, and used as a sample for evaluation. This sample for evaluation was attached to goniophotometer GP-1-3D (manufactured by Optec. Co., Ltd. (OPTEC. Co., Ltd.) and irradiated directional light falling under the direction of -5° with respect to the sample surface. The direction of specular reflection is defined as 0° and performed scanning from -5° to 30° to determine the intensity of the reflected light in a dark room conditions, evaluating thus, the property of the diffuse reflection. The results of Example 3, Comparative example 1 and Comparative example 3 are shown as typical examples in Fig. The gain deferred on the vertical axis representing the intensity of reflected light was calculated as follows: the same evaluation was performed using the standard scattering plate consisting of barium sulfate, and obtained for her the intensity of the reflected light in the direction of specular reflection was defined as 1. The gain was determined by normaliz is the intensity of the reflected light to the optical films of Example 1, Comparative example 1 and Comparative example 3 in the direction of 20° with respect to the direction of specular reflection. Assessment opacity

In order to eliminate the influence of the reflection on the rear surface, each optical film attached to a black acrylic plate through in between sticky substance, bounding with pressure, and used as a sample for evaluation. Then the measurements were performed with an integrating sphere spectrophotometer SP-64, manufactured by X-Rite Inc. ("Ex-Wright Inc."), the optical system d/8°, in which the scattered light is directed to the sample surface, and the reflected light is measured by a detector located in a position inclined at an angle of 8° with respect to the direction of the normal of the sample. For the measured values was used SPEX mode, which clears the specular reflection components and are detected only components of the diffuse reflection, and the measurement was made at viewing angle of detection of 2°. Note that the experiments it was confirmed that the measured opacity correlates with the feeling of opacity, which is observed visually. The results are shown in Table 1. In addition, Fig shows the relationship between the ratio of maximum amplitude (A) / minimum d is in (λ) of a wave" and opacity.

Evaluation of antireflection properties

Open a fluorescent lamp was reflected in each of the optical film, and the degree of blurring of the reflected image was evaluated based on the following standard. The results are shown in Table 1.

outlines of the fluorescent lamps were not distinguishable. (Two fluorescent lamps are seen as one fluorescent lamp.)

: fluorescent lamps could be distinguished to some extent, but their outlines were blurred.

x: the fluorescent lamp was reflected in the form in which they were. Estimating total light transmittance, haze and internal haze

Full light transmittance and haze were measured in accordance with Japanese industrial standards JIS K-7361 and JISK K-7136 through device NM-150, manufactured by Murakami Color Research Laboratory Co., Ltd. ("Murakami Feces Research Laboratory Co., Ltd."). Film from triacetylcellulose was attached to the surface of each optical film by means located between the transparent adhesive substance, bounding with pressure, and then was measured matte. The internal haze was determined by subtracting the haze of the attached film from triacetylcellulose of the Mat, measured as described above (so that the correct part, representing the matte surface). The results are shown in Table 1.

Evaluation of hardness when scratched with a pencil

Each optical film was attached to a glass plate and was evaluated in accordance with the method of testing the hardness scratching pencils, defined in Japanese industrial standard K-5400. The results are shown in Table 1.

Evaluation of electrical resistance

The surface electrical resistance was measured by compression to the surface of the antireflection film of the measuring pin head (MCP) with a resistivity meter (manufactured by Mitsubishi Chemical Corporation ("Mitsubishi Chemical Corporation), brand name: Hiresta UP). Note that the electrical resistance was measured at ambient conditions: 23°C and 60% relative humidity and at a voltage of 1000 C. the Results are shown in Table 2.

In Tables 1 and 2 shows the results of the assessments described above.

Table 1
The ratio a/λAnti-
glare property
Opacity (%)Full light transmittance (%) Haze (%)The internal haze (%)The hardness scratching pencils
Example 10,01080,6492,310,22H
Example 20,00980,5792,31,10,32H
Example 30,00710,4292,30,90,22H
Example 40,00510,2892,21,10,32H
Example 50,0027 0,2292,210,22H
Comparative example 1-0,65for 91.311,25,92H
Comparative example 20,1253,8590,815,10,3In
Comparative example 30,01621,0592,21,30,22H
Comparative example 40,01370,8892,21,30,22H
Comparative example 50,01270,8592,21,20,22H
Comparative example 60,002x0,1792,510,32H

Table 2
The surface electrical resistance (Ohm/sq)
Example 11014or more
Example 6of 1.30×1010
Example 7of 3.80×109

From the above evaluation results, you can understand the following.

Comparing the opacity (table 1) and the property of the diffuse reflection (Fig) from Example 3, Comparative example 1 and Comparative example 3, it is seen that the feeling of opacity can be reduced by reducing the intensity of light components diffracted from the direction of specular reflection in a wide angular range.

With regard to the properties of the diffuse reflection from example 3 and Comparative example 3, it was found that the light intensity is greatly reduced at a certain angle compared to the light intensity of Comparative example 1 in which the concave-convex shape formed on the surface with small particles. This shows that the optical film of Example 3 can eliminate the feeling of opacity, while maintaining the level antireflection characteristics in comparison with the optical film, described in Comparative example 1.

The ratio of the maximum amplitude (A) / minimum length (λ) of the wave can be easily adjusted, while maintaining the wave profile by changing the thickness of the layer of resin.

According to the Examples 1 to 5 and Comparative examples 2 through 6 opacity you can do is 0.7 or less, while maintaining the antireflection property, adjusting this ratio maximum amplitude (A) / minimum length (λ) of the wave so that it ranged from 0,0025 up to 0.011.

In Examples 1 through 5, since the hard coating layer contains fine particles, then, of course, the Mat is small, and the total transmittance is large. Thus, the optical films of Examples 1 to 5 show a high contrast due to the combination of high sitepronews is emote and low opacity.

Antireflection film located on the extreme outer surface of the display, also need such a property, as a hard coating, in order to protect the display surface. As shown in the evaluation results of hardness when scratched with a pencil, are shown in Table 1, the hard coating layer is necessary because the film from triacetylcellulose is soft (Comparative example 2). When the surface of the film from triacetylcellulose, which was moved form, is applied to the solid substance of the coating, the difference in height between a concavity and a convexity decreases. Therefore, in order to achieve the desired antireflection properties and opacity, it is necessary that the difference in height between a concavity and a convexity of the film from triacetylcellulose with a transferred form in advance was maintained greater than the difference in height between a concavity and a convexity at the outer surface.

Optical film having an antistatic function can be manufactured in accordance with the procedures described in Examples 6 and 7.

Test examples

Tinily roller was replaced by the platen, the last sandblasting, (obtained through the mesh density of 200 lines/inch), and was reposted. Then similarly applied substance solid which CSOs coverage. On Fig shows the relationship between the antiglare property and the coating thickness of the optical films prepared using roller held sandblasting and laser engraved roller, and both cases are compared.

Evaluation of coating thickness

The resin was applied on a flat film of triacetylcellulose, which was not migrate, and by a contact thickness meter (manufactured TESA K.K.) was measured coating thickness.

According Fig antireflection property of the optical film on which the transfer was made through the past sandblasting roller, abruptly disappears at a coating thickness of approximately 4 to 6 μm. In contrast, the antireflection property of the optical film on which the transfer was made through a laser engraved roller, which has the same height of the concavity - convexity, remained stable in the range of coating thickness from 7 to 12 μm. Thus, the optical film on which the transfer was made through a laser engraved roller, easy saves antireflection property at a high level and it is more preferable from the viewpoint of productivity.

As described above, in accordance with the optical film and method for manufacturing the optical film according to the present who have to the invention, you can implement the ideal optical film, which shows a high antireflection property, high contrast and high surface hardness.

We have described above the embodiments and Examples of the present invention, but the present invention is not limited variant implementations and Examples described above, and based on the technical ideas of the present invention may be made different changes.

For example, the numerical values, shapes, materials, structures, etc. described in the embodiments of the invention and the Examples described above are merely examples, and in accordance with demand can be used in other numerical values, shapes, materials, structures and the like, all of which differ from the above.

Moreover, the individual structural components of the variants of the invention from the first to the third, described above, can be combined with each other, if not distorted the essence of the present invention.

In addition, in embodiments of the invention described above have been described examples in which the present invention is applied to the optical films provided on the surfaces of the display in liquid crystal displays and methods of making such optical films. However, the present izopet which of these is not limited and is applicable to the optical film, used on surfaces displayed in various display devices such as displays, cathode ray tube (CRT), plasma display panel (PDP panel), displays based on the electroluminescence (EL) display on the basis of electronic emitters with surface conductivity (SED displays), and to methods of manufacturing such optical films. In addition, the size of the display device to which is applied the present invention is not particularly limited, and the present invention is applicable to all display devices range from small size to large size.

In addition, in embodiments of the invention described above, after phase transfer stamping and before the step of coating of the solid substances coating the base (11), to which was transferred the embossment may be subjected to the process of uniaxial tension or process biaxial stretching. When performing the process of stretching the structural components (11a) are stretched in one direction or two directions, and thus the structural components (11a) can be attributed to the shape anisotropy. For example, through a process of uniaxial tension form structural components (11a) can be changed with a truncated conical shape to a truncated elliptical cone shape.

The volume of Znanie reference positions

1:optical film
2:LCD panel
2A, 2b:the polarizer
3:the backlight
11:the item - basis
11a:structural component
11b:the gap between structural components
12:the layer of hard coating
13:the substance a solid coating
14:antistatic layer
15:antireflective layer
21:tinily cushion
22:reverse roller

1. Optical film, comprising:
basis with the convex structural components, which are two-dimensional and orderly formed directly on its surface; and
the solid layer is of the first coating, performed on the substrate surface, and the surface with specified structural components,
the surface of the hard coating layer has a continuous wave shape, such that approximately matches the shape of the structural components of the substrate surface,
the maximum amplitude (a) and the minimum length (λ) of a wave of continuous wavy surface are essentially constant, and
ratio (A/λ) max amplitude (A) the minimum length (λ) of a wave more than 0,002, but not more than to 0.011,
when the optical film has a total light transmittance of 92% or more, haze of 1.5% or less, the internal haze of 0.5% or less and an opacity of 0.7% or less.

2. The optical film according to claim 1, in which the cross-section of the layer of hard coating, obtained by incision along the straight line segment connecting the vertices adjacent structural components, has a continuous wave shape.

3. The optical film according to claim 2, in which the specified cross-section has a sinusoidal wave shape.

4. The optical film according to claim 1, in which the structural components are arranged in a hexagonal configuration.

5. The optical film according to claim 1,
in which structural components, when viewed from the top of any of the structural components are ordered in on the uh different directions, and
each of the cross-sections of the layer of hard coating, obtained by incision in the two different directions, has a continuous wave shape.

6. The optical film according to claim 1, in which the structural components have a hemispherical shape, a pyramidal shape or a columnar shape.

7. The optical film according to claim 1, in which the structural components on the substrate surface formed by stamping, and the height of the structural components is essentially the same.

8. The optical film according to claim 1, in which the refractive index of the basis is greater than the refractive index of the layer of hard coating.

9. The optical film according to claim 1, in which the base as a main component contains triacetylcellulose, or polyethylene terephthalate, or cycloolefin, or a copolymer of styrene and butadiene.

10. The optical film according to claim 1, in which the hard coating layer contains a thermosetting resin or a resin cured by ultraviolet radiation.

11. The optical film according to claim 1, in which the hard coating layer contains an antistatic agent.

12. The optical film according to claim 1, additionally containing an antistatic layer made between the base layer and hard coating.

13. The optical film according to claim 1, additionally containing antireflective layer is performed on the layer tverdokopchenye.

14. The optical film according to claim 1, in which the value of the concavity and convexity of the surface of the substrate greater than the magnitude of concavity and convexity of the surface layer of the hard coating.

15. A method of manufacturing an optical film, comprising stages, which are:
formed directly on the substrate surface convex structural components of two-dimensional and orderly manner;
moreover the structural components on the substrate surface is formed by transferring the concave-convex shape on the surface of the base using tinylogo roller
form the hard coating layer by coating on the surface of the base substance, solid coating, and the surface having the above structural components, and by curing substances solid cover,
in this case, the surface layer of the hard coating is formed of a continuous wave form, such that approximately matches the shape of the structural components of the substrate surface,
moreover, the maximum amplitude (a) and the minimum length (λ) of a wave of continuous wavy surface are essentially constant, and
ratio (A/λ) max amplitude (A) the minimum length (λ) of a wave more than 0,002, but not more than 0,011.

16. A method of manufacturing the optical film according to item 15, in which at the stage of forming the layer of solid coating ratio (A/λ regulate by changing the thickness of the solid substances of the coating, applied to the base surface, the surface having structural components.

17. Antiglare polarizer containing:
the polarizer and
the optical film placed on the polarizer,
when this optical film contains:
basis with the convex structural components, which are two-dimensional and orderly formed directly on its surface; and
the layer of hard coatings on the substrate surface, and the surface with these structural components,
moreover, the surface of the hard coating layer has a continuous wave shape, such that approximately matches the shape of the structural components of the substrate surface,
the maximum amplitude (a) and the minimum length (λ) of a wave of continuous wavy surface are essentially constant, and
ratio (A/λ) max amplitude (A) the minimum length (λ) of a wave more than 0,002, but not more than to 0.011,
when the optical film has a total light transmittance of 92% or more, haze of 1.5% or less, the internal haze of 0.5% or less and an opacity of 0.7% or less.

18. A display device, comprising:
a display unit for displaying the image; and
the optical film is placed on the side of the display surface in the display unit,
when this optical film contains:
basis with the convex structural components, which are two-dimensional and orderly formed directly on its surface; and
the layer of hard coatings on the substrate surface, and the surface having the above structural components,
moreover, the surface of the hard coating layer has a continuous wave shape, such that approximately matches the shape of the structural components of the substrate surface,
the maximum amplitude (a) and the minimum length (λ) of a wave of continuous wavy surface are essentially constant, and
ratio (A/λ) max amplitude (A) the minimum length (λ) of a wave more than 0,002, but not more than to 0.011,
when the optical film has a total light transmittance of 92% or more, haze of 1.5% or less, the internal haze of 0.5% or less and an opacity of 0.7% or less.



 

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Reflective coating // 2063056
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