JP2005088578A - Optical film, production method of optical film and antireflection film, polarizing plate and liquid crystal display device using the optical film - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an optical film excellent in planarity, adhesiveness and optical properties even when a thin and wide film excellent in environmental adaptability in the production is used, and provide a production method thereof, and an antireflection film, a polarizing plate and a liquid crystal display device each made by using the optical film. <P>SOLUTION: This optical film is produced by applying a coating composition for a cured resin layer onto a cellulose ester film substrate formed by melt-casting process to provide a cured resin layer thereon. Here, the coating composition for the cured resin layer comprises at least a resin and a solvent and contains 10-70 mass% solid content in the composition and ≥30 mass% water in total of solvents. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an optical film, a method for producing the optical film, and an antireflection film, a polarizing plate, and a liquid crystal display device using the optical film, and more specifically, an optical film excellent in flatness, smoothness, and optical properties, and an optical film. The present invention relates to a production method, and an antireflection film, a polarizing plate and a liquid crystal display device using the same.

  Cellulose ester films are used for transparent resin films (sometimes referred to simply as films) used in applications such as polarizing plate protective films for liquid crystal displays and polarizing plate protective films used in organic EL displays and the like. Several functional layers are provided to provide functions.

  For example, an antistatic layer for providing an antistatic function, a cured resin layer for improving surface hardness, a subbing layer for improving film adhesion, an anti-curl layer for preventing curling, or an anti-curling layer. For example, a glare layer and an antireflection layer.

  For example, the optical film described in Patent Document 1 has a cellulose ester film formed by a melt casting method. With this configuration, an optical film excellent in optical properties, physical properties, flatness, and adhesion can be obtained, and since an organic solvent is not used in the production of the film, the film is advantageous in terms of environment and cost.

  In addition, the cellulose ester film produced by the melt casting method contains additives such as a plasticizer and an ultraviolet absorber, as in the case of the cellulose ester film of the solution casting method that uses an organic solvent during normal production. However, these additives are added to improve the processability and moisture permeability of the cellulose ester film.

  However, although the cellulose ester film has excellent environmental characteristics and various performances, when a resin layer such as a cured resin layer is provided on the cellulose ester film by including these additives, usually, It was found that although the flatness and adhesion were improved as compared with the film produced by the solution casting method, it was not sufficient. In particular, it has been found that when a resin layer containing a large amount of an organic solvent is coated on the film, the flatness and adhesion deteriorated due to the diffusion of the organic solvent into the film.

  In addition, the planarity deteriorates when stored under high temperature and high humidity with the optical film coated with a cured resin layer containing a large amount of organic solvent on the cellulose ester film substrate produced by the melt casting method. A unique problem occurred. In this case, the portion where the flatness has deteriorated must be discarded, and the productivity is significantly reduced. In particular, a polarizing plate or an antireflection film used for the front surface of a display device has strict performance requirements, and an optical film having better flatness has been desired.

  As a method for reducing the amount of organic solvent used from the hard coat layer coating composition as much as possible, for example, Patent Document 2 discloses a method for forming a hard coat film and a composition for reducing the amount of organic solvent used as a hard coating composition. Although the composition is disclosed, the main purpose of the patent is a coating composition for applying to an optical member such as a plastic lens using an inkjet method, and is applied to a thin film and a wide cellulose ester film with high productivity. Had a problem.

As mentioned above, along with environmental issues related to film production, the recent trend is that there is a great demand for thinner display devices and larger display areas. Moreover, the thing of the width | variety is calculated | required and the request | requirement with respect to the flatness of the optical film surface and smoothness exists in the severer situation. However, by reducing the film thickness or increasing the width, the flatness and smoothness of the film surface tend to be inferior, and an immediate improvement of the above problem is desired.
JP 2000-352620 A JP 2003-126770 A

  Accordingly, an object of the present invention is to provide a thin film excellent in environmental suitability during production, an optical film excellent in flatness, adhesion, and optical characteristics even when a wide film is used, a method for producing the optical film, and the use thereof. The present invention provides an antireflection film, a polarizing plate and a liquid crystal display device.

  The above object of the present invention is achieved by the following configurations.

(Claim 1)
The coating composition for a cured resin layer containing at least a resin and a solvent contains 10% by mass to 70% by mass of a solid content, 30% by mass or more of moisture in all solvents, and the coating composition for a cured resin layer An optical film characterized in that a cured resin layer is provided on a cellulose ester film substrate formed by melt casting.

(Claim 2)
The optical film according to claim 1, wherein the cellulose ester film substrate contains two or more kinds of plasticizers.

(Claim 3)
The optical film according to claim 1, wherein the cured resin layer coating composition is coated on the cellulose ester film substrate and then cured by actinic radiation.

(Claim 4)
The optical film according to any one of claims 1 to 3, wherein the cellulose ester film substrate is subjected to a surface modification treatment before the coating composition for a cured resin layer is applied.

(Claim 5)
The optical film according to claim 4, wherein the surface modification treatment is corona discharge treatment, ultraviolet irradiation treatment, plasma discharge treatment, or alkali saponification treatment.

(Claim 6)
The optical film according to claim 1, wherein the solvent is a water-miscible organic solvent.

(Claim 7)
The optical film according to any one of claims 1 to 6, wherein a width of the cellulose ester film substrate is in a range of 1.4 m to 4 m.

(Claim 8)
The cellulose ester film substrate contains at least one selected from cellulose acetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, cellulose acetate butyrate, cellulose acetate phthalate, and cellulose phthalate. The optical film according to any one of claims 1 to 7.

(Claim 9)
The cellulose ester film substrate is a film stretched by 1.00 to 2.50 times and 1.01 to 3.00 times in one direction and a direction orthogonal thereto, respectively. 9. The optical film according to any one of 8 above.

(Claim 10)
The coating composition for a cured resin layer containing at least a resin and a solvent contains 10% by mass to 70% by mass of a solid content, 30% by mass or more of moisture in all solvents, and the coating composition for a cured resin layer It is a manufacturing method of the optical film which apply | coats on the cellulose-ester film base material formed by melt casting, and provides a cured resin layer, Comprising: This cellulose-ester film is 1.00-2. A method for producing an optical film, wherein the coating composition is applied on a cellulose ester film substrate stretched 50 times, 1.01 to 3.00 times, and further cured by actinic radiation.

(Claim 11)
The method for producing an optical film according to claim 10, wherein the cellulose ester film substrate is subjected to a surface modification treatment before the coating composition for a cured resin layer is applied.

(Claim 12)
The method for producing an optical film according to claim 11, wherein the surface modification treatment is corona discharge treatment, ultraviolet irradiation treatment, plasma discharge treatment, or alkali saponification treatment.

(Claim 13)
An antireflection film, comprising an antireflection layer provided on at least one surface of the optical film according to claim 1.

(Claim 14)
The antireflection layer has a low refractive index layer, the low refractive index layer contains inorganic fine particles, and the inorganic fine particles are porous particles or a composite particle having a coating layer provided on the surface of the porous particles; The antireflection film according to claim 13, wherein the antireflection film is a hollow particle filled with a solvent, a gas, or a porous material.

(Claim 15)
A polarizing plate using the optical film according to claim 1 on at least one surface.

(Claim 16)
A polarizing plate, wherein the antireflection film according to claim 13 or 14 is used on at least one surface.

(Claim 17)
A liquid crystal display device using the optical film according to claim 1.

(Claim 18)
A liquid crystal display device using the polarizing plate according to claim 15 or 16.

  According to the present invention, a thin film excellent in environmental suitability during production, an optical film excellent in flatness, adhesion, and optical characteristics even when a wide film is used, a method for producing an optical film, and a reflection using the same A prevention film, a polarizing plate, and a liquid crystal display device can be provided.

  Hereinafter, the best mode for carrying out the present invention will be described in detail, but the present invention is not limited thereto.

  The present invention has been made in view of the above circumstances, and in forming a cured resin layer continuously on a resin film as a thin film, the coating composition containing at least a resin and a solvent has a solid content of 10% by mass to 10% by mass. 70% by mass, containing 30% by mass or more of moisture in the total solvent, and applying the coating composition onto a cellulose ester film substrate formed by a melt casting method to provide a cured resin layer And

  As described above, the cellulose ester film base material produced by the melt casting method is greatly excellent in environmental suitability. However, when a coating composition containing a large amount of an organic solvent is applied onto the base material, Although the flatness was slightly improved as compared with the cellulose ester film substrate produced by the solution casting method, it was found that the improvement width was not sufficient. According to the study of the present inventor, the reason is not clear, but the cellulose ester film substrate produced by the melt casting method is a diffused organic solvent due to the penetration of the organic solvent from the coating composition into the substrate. It was assumed that the plasticity and ultraviolet absorber in the base material moved and diffused, resulting in deterioration of flatness. It was also found that a specific plasticizer is easily affected by the influence.

  That is, in the first invention, the organic solvent used in the coating composition for the cured resin layer applied on the cellulose ester film substrate produced by the melt casting method is replaced with a mixed system of water and the organic solvent. Thus, planarity deterioration due to diffusion of the organic solvent is improved. In the second invention, the planarity can be further improved by replacing a specific plasticizer in the cellulose ester film base material, which adversely affects the planarity by diffusion of the organic solvent, with a plasticizer having less influence. The present invention provides a comprehensively excellent optical film and a method for producing the same. In addition, by using the optical film, an antireflection film having excellent optical characteristics, a polarizing plate, and a liquid crystal display device excellent in visibility are provided.

  Hereinafter, the present invention will be described in more detail.

<Cellulose ester film substrate>
The optical film of the present invention is characterized by using a cellulose ester film substrate formed by a melt casting method. Since the amount of organic solvent used during film production can be greatly reduced by the melt casting method, the environmental suitability is greatly improved compared to the solution casting method using a large amount of conventional organic solvents. Is obtained.

  The melt casting in the present invention is a method in which a cellulose ester is heated and melted to a temperature showing fluidity without substantially using a solvent, and a film is formed using this, for example, by extruding a fluid cellulose ester from a die. This is a method of forming a film.

  The flowable cellulose ester, which may contain various additives used for casting, contains almost no volatile solvent, while a solvent may be used in part of the process for preparing the molten cellulose ester.

  The cellulose ester film constituting the optical film is not particularly limited. For example, an aromatic carboxylic acid ester or the like is also used, but it is preferable to use a lower fatty acid ester of cellulose. The lower fatty acid in the lower fatty acid ester of cellulose means a fatty acid having 6 or less carbon atoms. For example, cellulose acetate, cellulose propionate, cellulose butyrate and the like are preferable as the lower fatty acid ester of cellulose. In addition, mixed fatty acid esters such as cellulose acetate propionate and cellulose acetate butyrate can be used. The most preferred lower fatty acid ester of cellulose has an acyl group having 2 to 4 carbon atoms as a substituent, and when the substitution degree of acetyl group is X and the substitution degree of propionyl group or butyryl group is Y, the following formula ( It is a cellulose ester containing the cellulose ester which satisfy | fills I) and (II) simultaneously.

Formula (I) 2.6 ≦ X + Y ≦ 3.0
Formula (II) 0 ≦ X ≦ 2.5
Of these, cellulose acetate propionate is particularly preferably used. Among them, 1.9 ≦ X ≦ 2.5 and 0.1 ≦ Y ≦ 0.9 are preferable. The portion not substituted with an acyl group usually exists as a hydroxyl group. These can be synthesized by known methods.

  The cellulose ester used in the present invention has a weight average molecular weight Mw / number average molecular weight Mn ratio of 1.0 to 5.5, particularly preferably 1.4 to 5.0, and more preferably 2 0.0-3.0.

  The average molecular weight and molecular weight distribution of the cellulose ester can be measured by a known method using high performance liquid chromatography. Using this, the number average molecular weight and the weight average molecular weight are calculated.

The measurement conditions are as follows.
Solvent: Methylene chloride column: Shodex K806, K805, K803G (used by connecting 3 products manufactured by Showa Denko KK)
Column temperature: 25 ° C
Sample concentration: 0.1% by mass
Detector: RI Model 504 (manufactured by GL Sciences)
Pump: L6000 (manufactured by Hitachi, Ltd.)
Flow rate: 1.0ml / min
Calibration curve: Standard polystyrene STK standard polystyrene (manufactured by Tosoh Corp.) Mw = 100000-500 calibration curves with 13 samples were used. It is preferable that the 13 samples are substantially equally spaced.

  The cellulose ester raw material cellulose used in the present invention may be wood pulp or cotton linter, and the wood pulp may be softwood or hardwood, but softwood is more preferred. A cotton linter is preferably used from the viewpoint of peelability during film formation. The cellulose ester made from these can be mixed suitably or can be used independently.

  For example, the ratio of cellulose ester derived from cellulose linter: cellulose ester derived from wood pulp (coniferous): cellulose ester derived from wood pulp (hardwood) is 100: 0: 0, 90: 10: 0, 85: 15: 0, 50:50: 0, 20: 80: 0, 10: 90: 0, 0: 100: 0, 0: 0: 100, 80:10:10, 85: 0: 15, 40:30:30.

  Moreover, it is preferable that the cellulose ester used by this invention is a thing with few bright spot foreign materials when it is made into a film. A bright spot foreign material is an arrangement in which two polarizing plates are arranged orthogonally (crossed Nicols), a cellulose ester film is arranged between them, light from the light source is applied from one side, and the cellulose ester film is applied from the other side. This is the point where the light from the light source appears to leak when observed. At this time, the polarizing plate used for the evaluation is desirably composed of a protective film having no bright spot foreign matter, and a polarizing plate using a glass plate for protecting the polarizer is preferably used. The bright spot foreign matter is considered to be one of the causes due to the unacetylated or low acetylated cellulose contained in the cellulose ester, and it is removed by using a cellulose ester with less bright spot foreign matter and filtering the molten cellulose ester. And can be reduced. Further, the thinner the film thickness, the smaller the number of bright spot foreign matter per unit area, and the lower the content of cellulose ester contained in the film, the fewer bright spot foreign matter.

The bright spot foreign matter preferably has a bright spot diameter of 0.01 mm or more and 200 pieces / cm ² or less, more preferably 100 pieces / cm ² or less, and preferably 50 pieces / cm ² or less. 30 / cm ² or less, preferably 10 / cm ² or less, and most preferably none. Moreover, it is preferable that it is 200 pieces / cm < ² > or less also about a bright spot of 0.005-0.01 mm or less, Furthermore, it is preferable that it is 100 pieces / cm < ² > or less, and it is 50 pieces / cm < ² > or less. The number is preferably 30 pieces / cm ² or less, more preferably 10 pieces / cm ² or less, and most preferably none.

  When removing bright spot foreign matter by filtration, it is more effective to filter a composition containing a plasticizer, a deterioration inhibitor, an antioxidant and the like than to filter a melted cellulose ester alone. High removal efficiency is preferable. Of course, the cellulose ester may be dissolved in a solvent during the synthesis and reduced by filtration. It is possible to filter a mixture of UV absorbers and other additives as appropriate. Filtration is preferably performed with a melt containing cellulose ester having a viscosity of 10,000 P or less, more preferably 5000 P or less, still more preferably 1000 P or less, and even more preferably 500 P or less. As the filter medium, conventionally known materials such as glass fibers, cellulose fibers, filter paper, and fluorine resins such as tetrafluoroethylene resin are preferably used, and ceramics and metals are particularly preferably used. The absolute filtration accuracy is preferably 50 μm or less, more preferably 30 μm or less, still more preferably 10 μm or less, and even more preferably 5 μm or less. These can be used in combination as appropriate. The filter medium can be either a surface type or a depth type, but the depth type is preferably used because it is relatively less clogged.

  In another embodiment, it is preferable to use a cellulose ester obtained by dissolving a cellulose ester as a raw material at least once in a solvent and then drying the solvent. Preferably, cellulose ester that has been dissolved in a solvent together with at least one of a plasticizer, an ultraviolet absorber, a deterioration inhibitor, an antioxidant, and a matting agent and then dried is used. Furthermore, it is more preferable that it is cooled to −20 ° C. or lower during the dissolution process. It is preferable to add such a cellulose ester because it is easy to make each additive uniform when it is in a molten state, and it is also excellent for making optical properties uniform. In particular, it is preferable to add 1% by mass or more of the total cellulose ester, more preferably 5% by mass or more, more preferably 10% by mass or more, further preferably 30% by mass or more, and further preferably 50% by mass or more, most preferably. It is desirable that all cellulose ester raw materials are once dissolved in a solvent.

  The optical film of the present invention may be appropriately mixed with polymer components other than cellulose ester. The polymer component to be mixed is preferably one having excellent compatibility with the cellulose ester, and the transmittance when formed into a film is preferably 80% or more, more preferably 90% or more, and further preferably 92% or more.

  Although the manufacturing method of the optical film of this invention is demonstrated in more detail below, this invention is not limited to this. In this, the longitudinal direction means the film forming direction (longitudinal direction) of the film, and the transverse direction (lateral direction) means the direction perpendicular to the film forming direction of the film.

  The raw material cellulose ester is molded into pellets, dried with hot air or vacuum, then melt extruded, extruded into a sheet from a T-die, closely attached to a cooling drum by an electrostatic application method, etc., cooled and solidified, and unstretched sheet Get. The temperature of the cooling drum is preferably maintained at 90 to 150 ° C.

  When a polarizing plate is produced using the optical film of the present invention as a polarizing plate protective film, the cellulose ester film is particularly preferably a film stretched in the width direction or the film forming direction.

  The unstretched sheet obtained by peeling from the cooling drum described above is heated within a range of Tg + 100 ° C. from the glass transition temperature (Tg) of the cellulose ester via a heating device such as a plurality of roll groups and / or an infrared heater, It is preferable to perform single-stage or multistage longitudinal stretching.

  Next, it is preferable that the cellulose ester film stretched in the longitudinal direction obtained as described above is stretched in the temperature range of Tg to Tg-20 ° C. and then heat-set.

  In the case of transverse stretching, it is preferable to perform transverse stretching while sequentially raising the temperature difference in the range of 1 to 50 ° C. in a stretching region divided into two or more, because the distribution of physical properties in the width direction can be reduced. Further, after the transverse stretching, it is preferable that the film is held at a temperature of Tg-40 ° C. or higher at a temperature equal to or lower than the final transverse stretching temperature for 0.01 to 5 minutes because the distribution of physical properties in the width direction can be further reduced.

  In the heat setting, heat setting is usually performed for 0.5 to 300 seconds at a temperature higher than the final transverse stretching temperature and within a temperature range of Tg-20 ° C or lower. At this time, it is preferable to heat-fix while sequentially raising the temperature difference in the range of 1 to 100 ° C. in the region divided into two or more.

  The heat-set film is usually cooled to Tg or less, and clip holding portions at both ends of the film are cut and wound. At this time, it is preferable to perform a relaxation treatment of 0.1 to 10% in the horizontal direction and / or the vertical direction within the temperature range of the final heat setting temperature or lower and Tg or higher. In addition, it is preferable that the cooling is gradually performed from the final heat setting temperature to Tg at a cooling rate of 100 ° C. or less per second. Means for cooling and relaxation treatment are not particularly limited, and can be performed by a conventionally known means. In particular, it is preferable to carry out these treatments while sequentially cooling in a plurality of temperature ranges in terms of improving the dimensional stability of the film. The cooling rate is a value obtained by (T1-Tg) / t, where T1 is the final heat setting temperature and t is the time until the film reaches Tg from the final heat setting temperature.

  More optimal conditions of these heat setting conditions, cooling, and relaxation treatment conditions vary depending on the cellulose ester constituting the film, so the physical properties of the obtained biaxially stretched film should be measured and adjusted appropriately to have desirable characteristics. It may be determined by.

  When a polarizing plate is produced using the optical film of the present invention as a polarizing plate protective film, the Tg of the cellulose ester film is preferably 150 ° C. or higher, and more preferably 180 ° C. or higher. Tg is obtained as an average value of the temperature at which the baseline measured by the differential scanning calorimeter begins to deviate and the temperature at which the baseline returns to the baseline. The melting temperature is preferably in the range of 110 to 280 ° C, more preferably 200 ° C or higher.

  The preferred stretch ratio of the cellulose ester film is that the stretch ratio in one direction is stretched to 1.01 to 3.00 times, and the other stretch ratio is stretched to 1.00 to 2.50 times. More preferably, the stretch ratio in one direction is 1.01 to 3.00 and the other stretch ratio is stretched to 1.00 to 2.50, more preferably in one direction. The draw ratio is stretched to 1.01 to 3.00 times, and the other stretch ratio is stretched to 1.00 to 2.00 times. More preferably, the stretch ratio in one direction is 1.01 to 1.01. The film is stretched 3.00 times, and the other stretch ratio is stretched to less than 1.01-1.50 times, and more preferably, the stretch ratio in one direction is 1.01-3.00 times. The other draw ratio is less than 1.01 to 1.25 times More preferably, the stretch ratio in one direction is stretched to 1.01 to 2.50 times, and the other stretch ratio is stretched to less than 1.01 to 1.25 times. . Accordingly, a cellulose ester film excellent in optical isotropy can be preferably obtained, and a cellulose ester film having excellent flatness can be obtained. It is preferable to perform the width maintenance or the transverse stretching in the film forming process by a tenter, and it may be a pin tenter or a clip tenter.

  The stretching of the cellulose ester film is preferably performed before coating the cured resin layer in order to maintain excellent flatness.

  When the optical film of the present invention is a polarizing plate protective film, the thickness of the protective film is preferably 10 to 500 μm. 10-100 micrometers is especially preferable, 20-80 micrometers is preferable, Especially preferably, it is 30-60 micrometers.

  The film of the present invention preferably has a width of 1 to 4 m.

  When the cured resin layer of the present invention is applied, an optical film excellent in flatness can be obtained, so that it can be applied to a wide cellulose ester film. In particular, those having a width of 1.4 to 4 m are preferably used, and particularly preferably 1.4 to 2 m. If it exceeds 4 m, conveyance becomes difficult.

  The in-plane retardation value (Ro) of the cellulose ester film according to the present invention is preferably 0 to 70 nm or less. More preferably, it is 0-30 nm or less, More preferably, it is 0-10 nm or less.

  The retardation values (Ro) and (Rt) can be obtained by the following formula.

Ro = (nx−ny) × d
Rt = ((nx + ny) / 2−nz) × d
Here, d is the thickness (nm) of the film, the refractive index nx (also referred to as the maximum refractive index in the plane of the film, the refractive index in the slow axis direction), ny (in the direction perpendicular to the slow axis in the film plane). ) (Refractive index of film in the thickness direction).

  The retardation values (Ro) and (Rt) can be measured using an automatic birefringence meter. For example, it can be obtained at a wavelength of 590 nm using KOBRA-21ADH (Oji Scientific Instruments) under an environment of 23 ° C. and 55% RH.

  The slow axis is preferably in the width direction ± 1 ° of the film or in the longitudinal direction ± 1 °.

  Furthermore, the cellulose ester film of the present invention preferably has a residual organic solvent amount of less than 0.1% by mass in order to stabilize the flatness and retardation during storage. That is, if the amount of residual organic solvent, especially methylene chloride, methyl acetate, etc. is less than 0.1% by mass, the flatness during roll storage is particularly stable, and the value of retardation Rt in the film thickness direction is stable. It was. In the polarizing plate protective film, it is required to obtain a stable optical characteristic that the fluctuation of Rt is small. As a result of repeated studies to obtain a cellulose ester film having a stable Rt, it has been clarified that Rt varies depending on the amount of residual organic solvent of the cellulose ester film itself. The produced cellulose ester film is stored and transported in the form of a long roll (roll) and used for polarizing plate production and the like. In the wound state, the volatilization of the residual organic solvent from the cellulose ester film itself is scarce, especially the one wound up with a length of 100 m or more has less volatilization of the residual organic solvent over time. It has a distribution in the amount of residual organic solvent between the center and the outermost surface. For this reason, there has been a problem of having an Rt distribution in the winding. Further, since the amount of residual organic solvent varies depending on the storage period or storage conditions, it was difficult to produce a polarizing plate in a stable state of Rt or while confirming a stable Rt value.

  Since the optical film of the present invention does not substantially use a solvent in the film forming step, the amount of residual organic solvent contained in the cellulose ester film wound up after film formation is stably less than 0.1% by mass. With this, it is possible to provide a cellulose ester film having more stable flatness and Rt than before. In particular, it has become possible to provide a cellulose ester film having stable planarity and Rt even in a long roll of 100 m or longer. The cellulose ester film is not particularly limited as to the winding length, and is preferably used even if it is 1500 m, 2500 m, or 5000 m. Rt is 500 nm or less, more preferably 300 nm or less, more preferably 0 to 150 nm or less, and still more preferably 30 to 100 nm. Further, the variation of Rt and the width of the distribution are preferably less than ± 50%, preferably less than ± 30%, and preferably less than ± 20%. Further, it is preferably less than ± 15%, preferably less than ± 10%, preferably less than ± 5%, particularly preferably less than ± 1%. Most preferably, there is no variation in Rt.

  The residual organic solvent amount is particularly preferably less than 0.08% by mass, more preferably less than 0.05% by mass, and further preferably less than 0.03% by mass. In particular, in the state of a roll (roll), it is desirable to be in the above range from the center to the surface (outside).

  The amount of residual organic solvent can be measured by the headspace gas chromatography method. That is, a known amount of cellulose ester film is heated in a sealed container at 120 ° C. for 20 minutes, and the organic solvent contained in the gas phase in the sealed container is quantified by gas chromatography. From this result, the residual organic solvent amount (%) can be calculated.

Residual organic solvent amount (%) = residual organic solvent mass (g) / cellulose ester film before heat treatment (g)
Alternatively, the residual organic solvent amount (%) can be obtained from the mass change before and after heating by the following formula.

Residual organic solvent amount (%) = mass difference between cellulose ester films before and after heat treatment (g) / cellulose ester film before heat treatment (g)
When the film contains moisture, the moisture content (g) contained in the cellulose ester film is further determined by another method, and the mass of moisture (g) from the mass difference (g) of the cellulose ester film before and after the heat treatment. The residual organic solvent content (%) can be obtained from the value obtained by subtracting ()).

  It is difficult to reduce the residual organic solvent amount (%) of the cellulose ester film produced by the solution casting method to 0.1% by mass or less, and this requires a long drying step. For example, a cellulose ester film having a very low residual organic solvent content can be obtained at low cost, and a cellulose ester film having excellent characteristics as an optical film can be obtained.

  The optical film of the present invention may contain, in addition to cellulose ester, a plasticizer, an ultraviolet absorber, a slip agent, a deterioration inhibitor, an antioxidant, a stabilizer, a matting agent, and the like.

  Examples of the plasticizer include triphenyl phosphate, tricresyl phosphate, cresyl phenyl phosphate, octyl diphenyl phosphate, diphenyl biphenyl phosphate, trioctyl phosphate, tributyl phosphate, trinaphthyl phosphate, trixyl phosphate, tris ortho-biphenyl phosphate, 1,4 -Phosphate plasticizers such as phenylene-tetraphenyl phosphate, phthalate plasticizers such as diethyl phthalate, dimethoxyethyl phthalate, dimethyl phthalate, dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, triacetin, Tributyltyrin, butyl phthalyl butyl glycolate, ethyl phthalyl ethyl glycolate, methyl phthalate Ethyl glycolate, butyl phthalyl butyl glycolate, etc. glycolic acid ester based plasticizers. Of these, phthalate ester and glycolate ester plasticizers are preferred because they hardly cause hydrolysis of cellulose esters.

In particular, among plasticizers, those having non-volatility are preferably used. The non-volatile plasticizer is a compound having a vapor pressure at 200 ° C. of 1330 Pa or less, having a very low vapor pressure and low volatility. Preferably it is 665 Pa or less, More preferably, it is 133 Pa or less. Specific examples include nonvolatile phosphate esters described in JP-A-6-501040, and arylene bis (diaryl phosphate) esters are preferred, for example.
Specific examples of preferred plasticizers in the present invention are illustrated below.

  In particular, the cellulose ester film used in the present invention preferably contains at least two kinds of plasticizers, and at least one kind is preferably a polyhydric alcohol ester type plasticizer. Other plasticizers are not particularly limited. Preferably, a polyhydric alcohol ester, a phthalic acid ester, a citric acid ester, a fatty acid ester, a phosphoric acid ester, a glycolate plasticizer, and the like, which are different from the polyhydric alcohol ester plasticizer, are used.

  The polyhydric alcohol ester plasticizer is a plasticizer comprising an ester of a dihydric or higher aliphatic polyhydric alcohol and a monocarboxylic acid, and preferably has an aromatic ring or a cycloalkyl ring in the molecule. Preferably it is a 2-20 valent aliphatic polyhydric alcohol ester.

  The polyhydric alcohol used in the present invention is represented by the following general formula (1).

Formula (1) R _1- (OH) n
However, R ₁ represents an n-valent organic group, n represents a positive integer of 2 or more, and the OH group represents an alcoholic and / or phenolic hydroxyl group.

  Examples of preferred polyhydric alcohols include the following, but the present invention is not limited to these. Adonitol, arabitol, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,2-propanediol, 1,3-propanediol, dipropylene glycol, tripropylene glycol, 1,2-butanediol, 1,3- Butanediol, 1,4-butanediol, dibutylene glycol, 1,2,4-butanetriol, 1,5-pentanediol, 1,6-hexanediol, hexanetriol, galactitol, mannitol, 3-methylpentane- Examples include 1,3,5-triol, pinacol, sorbitol, trimethylolpropane, trimethylolethane, and xylitol. In particular, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, sorbitol, trimethylolpropane, and xylitol are preferable.

  There is no restriction | limiting in particular as monocarboxylic acid used for the polyhydric alcohol ester of this invention, Well-known aliphatic monocarboxylic acid, alicyclic monocarboxylic acid, aromatic monocarboxylic acid, etc. can be used. Use of an alicyclic monocarboxylic acid or aromatic monocarboxylic acid is preferred in terms of improving moisture permeability and retention.

  Examples of preferred monocarboxylic acids include the following, but the present invention is not limited thereto.

  As the aliphatic monocarboxylic acid, a fatty acid having a straight chain or a side chain having 1 to 32 carbon atoms can be preferably used. The number of carbon atoms is more preferably 1-20, and particularly preferably 1-10. When acetic acid is contained, the compatibility with the cellulose ester is increased, and it is also preferable to use a mixture of acetic acid and another monocarboxylic acid.

  Preferred aliphatic monocarboxylic acids include acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, enanthic acid, caprylic acid, pelargonic acid, capric acid, 2-ethyl-hexanoic acid, undecylic acid, lauric acid, tridecylic acid, Saturated fatty acids such as myristic acid, pentadecylic acid, palmitic acid, heptadecylic acid, stearic acid, nonadecanoic acid, arachidic acid, behenic acid, lignoceric acid, serotic acid, heptacosanoic acid, montanic acid, melicic acid, laccelic acid, undecylenic acid, olein Examples thereof include unsaturated fatty acids such as acid, sorbic acid, linoleic acid, linolenic acid, and arachidonic acid.

  Examples of preferable alicyclic monocarboxylic acids include cyclopentanecarboxylic acid, cyclohexanecarboxylic acid, cyclooctanecarboxylic acid, and derivatives thereof.

  Examples of preferred aromatic monocarboxylic acids include those in which an alkyl group is introduced into the benzene ring of benzoic acid such as benzoic acid and toluic acid, and two or more benzene rings such as biphenylcarboxylic acid, naphthalenecarboxylic acid, and tetralincarboxylic acid. The aromatic monocarboxylic acid which has, or those derivatives can be mentioned. Benzoic acid is particularly preferable.

  The molecular weight of the polyhydric alcohol ester is not particularly limited, but is preferably 300 to 1500, and more preferably 350 to 750. A higher molecular weight is preferred because it is less likely to volatilize, and a smaller one is preferred in terms of moisture permeability and compatibility with cellulose ester.

  The carboxylic acid used for the polyhydric alcohol ester may be one kind or a mixture of two or more kinds. Moreover, all the OH groups in the polyhydric alcohol may be esterified, or a part of the OH groups may be left as they are.

  Below, the specific compound of a polyhydric alcohol ester is illustrated.

  The total content of the plasticizer in the cellulose ester film is preferably 5 to 20% by mass, more preferably 6 to 16% by mass, and particularly preferably 8 to 13% by mass with respect to the total solid content. The contents of the two kinds of plasticizers are each at least 1% by mass, preferably 2% by mass or more.

  The polyhydric alcohol ester plasticizer is preferably contained in an amount of 1 to 12% by mass, particularly preferably 3 to 11% by mass. If the amount is too small, deterioration of flatness is recognized, and if it is too large, bleeding out tends to occur. The mass ratio between the polyhydric alcohol ester plasticizer and the other plasticizer is preferably in the range of 1: 4 to 4: 1, more preferably 1: 3 to 3: 1. If the amount of the plasticizer added is too large or too small, the film is liable to be deformed, which is not preferable.

  As the ultraviolet absorber, those which are excellent in the ability to absorb ultraviolet rays having a wavelength of 370 nm or less from the viewpoint of preventing deterioration of the liquid crystal and have little absorption of visible light having a wavelength of 400 nm or more from the viewpoint of liquid crystal display properties are preferable. For example, “Latest Technology of Polymer Additives”, page 100 (1987) published by CMC Co., Ltd. Benzophenone, benzotriazole, acrylate, salicylate, oxanilide, hindered amine, nickel, triazine, etc. Is mentioned.

  Although the specific example of an ultraviolet absorber is given to the following, this invention is not limited to these.

UV-1: 2- (2'-hydroxy-5'-methylphenyl) benzotriazole UV-2: 2- (2'-hydroxy-3 ', 5'-di-tert-butylphenyl) benzotriazole UV-3 : 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) benzotriazole UV-4: 2- (2'-hydroxy-3 ', 5'-di-tert-butylphenyl)- 5-Chlorobenzotriazole UV-5: 2- (2'-hydroxy-3 '-(3 ", 4", 5 ", 6" -tetrahydrophthalimidomethyl) -5'-methylphenyl) benzotriazole UV-6: 2,2-methylenebis (4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol)
UV-7: 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) -5-chlorobenzotriazole UV-8: 2- (2H-benzotriazol-2-yl) -6 (Linear and side chain dodecyl) -4-methylphenol (TINUVIN 171: manufactured by Ciba)
UV-9: Octyl-3- [3-tert-butyl-4-hydroxy-5- (chloro-2H-benzotriazol-2-yl) phenyl] propionate and 2-ethylhexyl-3- [3-tert-butyl- Mixture of 4-hydroxy-5- (5-chloro-2H-benzotriazol-2-yl) phenyl] propionate (TINUVIN 109: manufactured by Ciba)
UV-10: 2,4-dihydroxybenzophenone UV-11: 2,2'-dihydroxy-4-methoxybenzophenone UV-12: 2-hydroxy-4-methoxy-5-sulfobenzophenone UV-13: Bis (2-methoxy -4-hydroxy-5-benzoylphenylmethane)
Further, as the UV absorber, a polymer UV absorber can be preferably used, and in particular, JP-A-6-148430, JP-A-2002-31715, JP-A-2002-47357, JP-A-2002-169020, JP-A-2003. The polymer type ultraviolet absorber described in No.-113317 is preferably used.

  In the present invention, the ultraviolet absorber is preferably added in an amount of 0.1 to 20% by mass, more preferably 0.5 to 10% by mass, and further preferably 1 to 5% by mass from the viewpoint of coloring. It is preferable.

  Two or more kinds of ultraviolet absorbers may be used in combination, and it is preferable to search for an optimal combination as appropriate depending on production conditions, use conditions, and the like.

  To the cellulose ester in the present invention, fine particles such as a matting agent can be added in order to impart slipperiness. Examples of the fine particles include fine particles of an inorganic compound or fine particles of an organic compound.

  As the inorganic compound, a compound containing silicon, silicon dioxide, aluminum oxide, zirconium oxide, calcium carbonate, talc, clay, calcined kaolin, calcined calcium silicate, hydrated calcium silicate, aluminum silicate, magnesium silicate, calcium phosphate, and the like are preferable. Preferred are inorganic compounds and zirconium oxide containing silicon, and silicon dioxide is particularly preferably used.

  As these fine particles, for example, commercially available products such as Aerosil R972, R972V, R974, R812, 200, 200V, 300, R202, OX50, and TT600 (above Nippon Aerosil Co., Ltd.) can be used.

  As the fine particles of zirconium oxide, commercially available products such as Aerosil R976 and R811 (manufactured by Nippon Aerosil Co., Ltd.) can be used.

  As the organic compound, for example, polymers such as silicone resin, fluorine resin, and acrylic resin are preferable, and among them, silicone resin is preferably used.

  Among the above silicone resins, those having a three-dimensional network structure are particularly preferable. For example, Tospearl 103, 105, 108, 120, 145, 3120 and 240 (above, manufactured by Toshiba Silicone Co., Ltd.) ) Etc. can be used.

  The primary average particle diameter of the fine particles according to the present invention is preferably 20 nm or less, more preferably 16 to 5 nm, and particularly preferably 12 to 5 nm, from the viewpoint of keeping the haze low.

  The primary average particle diameter of the fine particles according to the present invention is measured by observing particles with a transmission electron microscope (magnification of 500,000 to 2,000,000 times), observing 100 particles, and using the average value, the primary average particle size is measured. The diameter.

  These fine particles can be added by kneading by a conventional method. Particularly preferably, the fine particles previously dispersed in a solvent are mixed and dispersed with a cellulose ester and / or a plasticizer and / or an ultraviolet absorber, and then the solvent is added. It is preferable that the solid is made to be volatilized and used in the process of producing the cellulose ester melt in that a uniform melt is obtained. The addition amount of the fine particles is preferably 0.01 to 1% by mass, particularly preferably 0.05 to 0.3% by mass.

  The above optical film can be formed by referring to the method described in, for example, JP-T-6-501040.

  Moreover, in manufacturing the optical film described above, it is a preferable aspect to coat a cured resin layer after stretching. Various functional layers such as an antistatic layer, an antireflection layer, a slippery layer, an adhesive layer, an adhesive layer, an antiglare layer, an antifouling layer, an alignment layer, a liquid crystal layer, and a gas barrier layer may be applied. . For example, an intermediate layer such as an antistatic layer or an undercoat layer may be provided between the cellulose ester film and the cured resin layer.

  In the present invention, for the purpose of improving the adhesion between the coating composition for the cured resin layer and the substrate and further improving the wettability, the surface of the object to be coated is previously subjected to alkali saponification treatment, acid treatment, surfactant treatment, inorganic or organic matter. Surface modification treatment by polishing with fine particles, oxidant treatment, primer treatment, corona discharge treatment, ultraviolet irradiation treatment, plasma discharge treatment by high frequency discharge in argon or oxygen atmosphere, ion beam treatment of argon, oxygen or nitrogen, etc. It is preferable to carry out.

  Among these surface activation treatments, corona discharge treatment, ultraviolet irradiation treatment, plasma discharge treatment, or alkali saponification treatment is particularly preferred in practice.

  The corona discharge treatment is a treatment performed by applying a high voltage of 1 kV or higher between the electrodes at atmospheric pressure and discharging it, and is commercially available from Kasuga Electric Co., Ltd. and Toyo Electric Co., Ltd. It can be performed using an apparatus. The intensity of the corona discharge treatment depends on the distance between the electrodes, the output per unit area, and the generator frequency. As one electrode (A electrode) of the corona discharge treatment apparatus, a commercially available one can be used, but the material can be selected from aluminum, stainless steel and the like. The other is an electrode (B electrode) for holding a plastic film, and is a roll electrode installed at a certain distance from the A electrode so that the corona discharge treatment is carried out stably and uniformly. . A commercially available one can also be used, and the material is preferably a roll made of aluminum, stainless steel, or a metal thereof, and a roll lined with ceramic, silicon, EPT rubber, hyperon rubber, or the like. It is done.

  The frequency used for the corona discharge treatment of the present invention is a frequency of 20 kHz to 100 kHz, and a frequency of 30 kHz to 60 kHz is preferable. When the frequency is lowered, the uniformity of the corona discharge treatment is deteriorated, and unevenness of the corona discharge treatment occurs. In addition, when the frequency is increased, there is no particular problem when performing a high output corona discharge treatment, but when performing a low output corona discharge treatment, it becomes difficult to perform a stable treatment. Processing unevenness occurs.

The output of the corona discharge treatment of the present invention is 1 to 5 w · min. / M ² but ² to 4 w · min. An output of / m ² is preferred.

  The distance between the A electrode and the film of the present invention is from 5 mm to 50 mm, preferably from 10 mm to 35 mm. When the gap is opened, a higher voltage is required to maintain a constant output, and unevenness is likely to occur. On the other hand, if the gap is too narrow, the applied voltage becomes too low and unevenness is likely to occur. Furthermore, when the film is transported and continuously processed, the film comes into contact with the electrodes and scratches are generated.

Examples of the ultraviolet irradiation treatment include lamps such as metal halide lamps, xenon lamps, carbon arc lamps, chemical lamps, low pressure mercury lamps, and high pressure mercury lamps. For example, a commercially available product such as an H lamp, D lamp, or V lamp manufactured by Fusion System can be used. The metal halide lamp has a continuous spectrum as compared with a high-pressure mercury lamp (main wavelength is 365 nm), has high luminous efficiency in the range of 200 to 450 nm, and has a long wavelength range. Irradiation conditions vary depending on each lamp. For example, a low-pressure mercury lamp is used to irradiate mainly 185 nm and 254 nm ultraviolet rays with a light amount of 1 to 3,000 mJ / cm ² , and an excimer lamp is used mainly for the wavelength. Can irradiate ultraviolet rays of 172 nm with a light amount of 1 to 3,000 mJ / cm ² . Such ultraviolet rays generate active oxygen and ozone, and can decompose organic substances on the surface of the object to be coated. Also, they act directly on the surface of the object to be coated, so that hydroxyl groups and carboxyl groups are formed on the surface of the object to be coated. It is possible to generate a hydrophilic group such as a carbonyl group and improve adhesion.

  The plasma discharge treatment can be performed by exposing the base material to a high-frequency discharge atmosphere in an argon, helium, nitrogen, or oxygen atmosphere by a plasma discharge treatment apparatus described later. The discharge treatment is preferably performed under atmospheric pressure.

  The alkali saponification treatment is preferably carried out by immersing in an alkaline aqueous solution such as 0.1 to 10 mol / L sodium hydroxide or potassium hydroxide at room temperature to 60 ° C. for 1 to several minutes, followed by neutralization and washing with water. I can do it.

  After gripping the clip grips at both ends of the film cut during the film-forming process, or after performing granulation or depolymerization / repolymerization as necessary, as a raw material for film of the same type Or you may reuse as a raw material for films of a different kind. Also, a cellulose ester film having a laminated structure is produced by coextruding a composition containing cellulose esters having different additive concentrations such as the above-mentioned plasticizer, ultraviolet absorber, deterioration inhibitor, antioxidant, and matting agent. You can also. For example, a cellulose ester film having a structure of skin layer / core layer / skin layer can be produced. For example, the matting agent can be contained in the skin layer in a large amount or only in the skin layer. More plasticizers and UV absorbers can be added to the core layer than the skin layer, and may be added only to the core layer. In addition, the type of plasticizer and UV absorber can be changed between the core layer and the skin layer. For example, the skin layer contains a low volatility plasticizer and / or UV absorber, and the core layer has excellent plasticity. It is also possible to add a plasticizer or an ultraviolet absorber excellent in ultraviolet absorption. The Tg of the skin layer and the core layer may be different, and the Tg of the core layer is preferably lower than the Tg of the skin layer. Also, the viscosity of the melt containing the cellulose ester during melt casting may be different between the skin layer and the core layer, and the viscosity of the skin layer> the viscosity of the core layer or the viscosity of the core layer ≧ the viscosity of the skin layer may be used.

In the present invention, it is preferable that the vertical and horizontal dimensional shrinkage ratios of the cellulose ester film formed as described above at 105 ° C. for 5 hours are ± 0.1% or less. Moreover, it is preferable that the haze in 80 micrometer conversion of a cellulose-ester film is 0.6% or less, The thing whose haze value is 0.5% or less is especially preferable, More preferably, it is 0.1% or less. The lower limit of the haze value is not particularly limited. Further, the tear strength of the optical film of the present invention is preferably 10 g or more, more preferably 12 g or more, further preferably 15 g or more, further preferably 18 g or more, and 20 g or more. Is more preferable, and it is still more preferable that it is 22 g or more. The tensile strength of the cellulose ester film is preferably 50 N / mm ² or more, and the elastic modulus is preferably 3 kN / mm ² or more. The coefficient of dynamic friction of the cellulose ester film is 1 or less, preferably 0.4 or less, and more preferably 0.35 or less.

  The optical film of the present invention is excellent in dimensional stability, and the dimensional shrinkage at 80 ° C. and 90% RH is less than ± 0.5%, more preferably less than 0.3%, and still more preferably 0.1. %, More preferably less than 0.08%, still more preferably less than 0.06%, and even more preferably less than 0.04%.

<Actinic radiation curable resin layer>
The resin layer according to the present invention is a cured resin layer coated on a cellulose ester film.

  Furthermore, in the hard coat film of this invention, it is preferable that it is an active ray cured resin layer containing an active ray cured resin as a cured resin layer.

  The active ray curable resin layer of the optical film of the present invention will be described in detail.

  The feature of the present invention is that the coating composition for a cured resin layer containing at least a resin, moisture and an organic solvent contains 10% by mass to 70% by mass and 30% by mass or more of moisture as solid contents. With this configuration, an optical film with little deterioration in planarity can be obtained even when a cured resin layer is provided on a cellulose ester film produced by a melt casting method.

  The actinic radiation curable resin layer refers to a layer mainly composed of a resin that cures through a crosslinking reaction or the like by irradiation with actinic rays such as ultraviolet rays or electron beams. As the actinic radiation curable resin (polymerizable compound), a component containing a monomer having an ethylenically unsaturated double bond is preferably used, and cured by irradiating an actinic radiation such as an ultraviolet ray or an electron beam. Is formed. Typical examples of the actinic radiation curable resin include an ultraviolet curable resin and an electron beam curable resin, and a resin curable by ultraviolet irradiation is preferable.

  As the ultraviolet curable resin, for example, an ultraviolet curable urethane acrylate resin, an ultraviolet curable polyester acrylate resin, an ultraviolet curable epoxy acrylate resin, an ultraviolet curable polyol acrylate resin, or an ultraviolet curable epoxy resin is preferable. Used. Hereinafter, the polymerizable compound used in the present invention will be described.

(Polymerizable compound)
The polymerizable compound used in the present invention is a compound having an ethylenically unsaturated bond capable of radical polymerization and any compound having at least one ethylenically unsaturated bond capable of radical polymerization in the molecule. However, those having chemical forms such as monomers, oligomers and polymers are included. Only one kind of radically polymerizable compound may be used, or two or more kinds thereof may be used in combination at an arbitrary ratio in order to improve desired properties.

In addition, the compound having an ethylenically unsaturated bond capable of radical polymerization used in the present invention is preferably a compound having at least one carboxyl group in one molecule, and as such a compound, (1) 2 bases Reaction product of acid anhydride and hydroxy group-containing acrylic acid ester or methacrylic acid ester: representative compounds thereof include succinic anhydride, orthophthalic anhydride, maleic anhydride, 2-hydroxyethyl methacrylate, It is a reaction product with 3-chloro-2-hydroxypropyl methacrylate.

  (2) Compound obtained by reacting dibasic acid anhydride with secondary hydroxyl group of acrylic ester of epoxy resin: As representative compounds thereof, bisphenol type epoxy resin Epicoat 828, Epicoat 1001 (trade name; oil Deacol (trade name; manufactured by Nagase Kasei), such as 1,4-butanediol diglycidyl ether, trimethylolpropane diglycidyl ether, pentaerythrtriglycidyl ether, cyclic It can be obtained by reacting acrylate with aliphatic epoxy resin such as Celoxide (trade name; manufactured by Daicel Chemical Industries) and then reacting it with residual cocic anhydride or maleic anhydride. A compound.

  (3) A compound obtained by reacting a polybasic alcohol ester of acrylic acid or methacrylic acid with a dibasic acid anhydride: Typical examples of these compounds include succinic anhydride and maleic anhydride on glycol of acrylic acid or polyethylene glycol ester. It is a compound obtained by reacting. The glycol or polyethylene glycol used here preferably has a molecular weight of about 600 or less.

  (4) Water-soluble urethane acrylates and methacrylates having carboxyl side chains in the molecular chain: synthesis of oligomers as UV curable resins is known, but to synthesize oligomer compounds having carboxyl side chains, oligomers In the course of the synthesis reaction, a polybasic acid typified by trimellitic anhydride, or a compound having two hydroxyl groups and one carboxyl group in one molecule typified by dimethylolpropionic acid or the like is used. .

  In addition, the compounds (1) to (4) exemplified above are neutralized with a base and become easily soluble in water. Specific examples of the base used include ammonia, methylamine, ethylamine, dimethylamine, diethylamine, n-butylamine, di-n-butylamine, trimethylamine, ethylenediamine, diethylenetriamine, triethylenetetraamine, tetoaethylenepentamine, propylenediamine, and ethanol. Examples include amine, hexylamine, laurylamine, diethanolamine, triethanolamine, morpholine, piperidine, propylamine, isopropylamine, isobutylamine, NaOH, LiOH, and KOH.

  Moreover, a water-soluble radically polymerizable compound is mentioned as a polymeric compound used for this invention. Examples of such compounds include the following compounds, but the present invention is not limited thereto.

  X in the above formulas (1) to (4) and (13) represents a hydrogen atom or a methyl group.

  The polymerizable substance that undergoes radical polymerization by ultraviolet rays is selected from, for example, general formula group A in which R is a residue of a polyol in the following general formula, or general formula group B in which R is a residue of an epoxy ester of a polyol. And water-soluble polymerizable compounds. General formula groups A and B will be described later.

  When the above general formula is expressed more clearly, the following general formula is obtained.

  Furthermore, as the substance of the general formula group A, it is preferable to use those exemplified below. Here, A, X, Rx, Ry, Rz, and Rp in the polymerizable substance groups A1 to A11 represented by the following general formula independently represent the following atomic groups.

  In addition, as a halogen atom of X2 in the above formula (1-4) showing one of the structures of Rp, for example, a fluorine atom, a chlorine atom, a bromine atom or the like can be mentioned, and as an alkoxyl group, a carbon atom can be used. Examples are an alkoxyl group of 1 to 3 and the like.

  First, polymerizable compounds included in the polymerizable substance group A1 having the general formula shown below are exemplified, and specifically, the polymerizable compounds A1-1 and A1-2 represented by the following formula are used. I can do it.

  Moreover, although the polymeric compound contained in polymeric substance group A2 which consists of a general formula shown below is mentioned, Specifically, polymeric compound A2-1 represented by a following formula can be used.

  Moreover, although the polymeric compound contained in polymeric substance group A3 which consists of the general formula shown below is mentioned, Specifically, polymeric compound A3-1-A3-4 represented by a following formula should be used. I can do it.

  Moreover, although the polymeric compound contained in polymeric substance group A4 which consists of the general formula shown below is mentioned, Specifically, polymeric compound A4-1 represented by a following formula can be used.

  Moreover, although the polymeric compound contained in polymeric substance group A5 which consists of the general formula shown below is mentioned, Specifically, polymeric compound A5-1 represented by a following formula can be used.

  Furthermore, each polymeric compound contained in polymeric substance group A6-A11 which consists of a general formula shown below is mentioned.

  The polymerizable compounds A10-1 and A10-2 exemplified above can be produced by adding an amine having a carboxyl group to the vinyl group of acrylic acid, that is, a wide-ranging amine acid. That is, it is generally represented by the following formula.

  Here, R is a methylene group in the case of the polymerizable compound A10-1, and a phenylene group in the case of A10-2. Examples of the amine having a carboxyl group used in this method include paraaminobenzoic acid, glycine, valine, leucine, isoleucine, serine, threonine, methionine, and phenylalanine. In addition, substances having equivalent performance can be derived from amino acids having two carboxyl groups such as glutamic acid and aspartic acid.

  On the other hand, examples of the polymerizable compound belonging to the general formula group B include polymerizable substance groups B1 to B4 represented by the following general formula. In the general formulas of the polymerizable substance groups B1 to B4, A and Rp represent the following atomic groups.

  Among the many groups of compounds listed above, compounds having three polymerizable functional groups in the molecule are particularly excellent in the polymerization rate, the hardness of the cured product, and the water friction resistance. The main reason for this tendency is considered to be that when a compound having three or more reactive groups is polymerized, the crosslink density is high, and the polymer has an effect of greatly reducing hydrophilicity.

(Photopolymerization initiator)
The water-soluble photopolymerization initiator that constitutes the aqueous photocurable resin composition according to the present invention will be described. As an example, for example, a catalyst having a wavelength of up to about 400 nm may be mentioned. As such a catalyst, for example, a photopolymerization initiator represented by the following general formula (hereinafter abbreviated as TX type) which is a substance having a functionality in a long wavelength region, that is, a sensitivity to generate a radical upon receiving ultraviolet rays. In the present invention, it is particularly preferable to select and use them appropriately.

In the above general formulas TX-1 to TX-3, R ₂ represents — (CH ₂ ) x — (x = 0 or 1), —O— (CH ₂ ) y — (y = 1 or 2), substituted or not Represents a substituted phenylene group. When R ₂ is a phenylene group, at least one of the hydrogen atoms in the benzene ring is, for example, a carboxyl group or a salt thereof, a sulfonic acid or a salt thereof, a linear or branched chain having 1 to 4 carbon atoms. Even if it is substituted with one or more groups or atoms selected from alkyl groups, halogen atoms (fluorine, chlorine, bromine, etc.), C1-C4 alkoxyl groups, aryloxy groups such as phenoxy groups, etc. Good. M represents a hydrogen atom or an alkali metal (for example, Li, Na, K, etc.). Further, R ₃ and R ₄ each independently represent a hydrogen atom or a substituted or unsubstituted alkyl group. Examples of the alkyl group include a linear or branched alkyl group having about 1 to 10 carbon atoms, particularly about 1 to 3 carbon atoms. Examples of substituents for these alkyl groups include halogen atoms (fluorine atoms, chlorine atoms, sulfur atoms, etc.), hydroxyl groups, alkoxyl groups (about 1 to 3 carbon atoms), and the like. Moreover, m represents the integer of 1-10.

  Thioxanthone substituted with these hydrophilic atomic groups is water-soluble and co-soluble with an anionic aqueous pigment dispersion, and is less affected by the absorption of the organic pigment itself. Therefore, it is a highly sensitive catalyst in pigment-based compositions. Works.

  Furthermore, as the water-soluble photopolymerization initiator constituting the aqueous photocurable resin composition according to the present invention, a water-soluble derivative of a photopolymerization initiator Irgacure 2959 (trade name: manufactured by Ciba Specialty Chemicals) having the following general formula ( Hereinafter, the abbreviated IC system) can also be used. Specifically, IC-1 to IC-3 having the following formulas can be used.

  The above-described IC-1 to IC-3 are nonionic, but the wavelength region that can be sensitive to ultraviolet rays is shorter than the photopolymerization initiators shown as TX-1 to TX-3 mentioned above. In the area. Moreover, since IC-1 to IC-3 are water-soluble like the above-described TX-1 to TX-3, they are useful as components of the aqueous photocurable resin composition of the present invention. Furthermore, it is considered possible to produce an aqueous derivative from a catalyst material (photopolymerization initiator) for an existing ultraviolet polymerization system and use it as a photopolymerization initiator constituting the aqueous photocurable resin composition of the present invention. It is done.

  In addition, the following ultraviolet curable resins can be used as appropriate.

  UV curable acrylic urethane resins generally include 2-hydroxyethyl acrylate and 2-hydroxyethyl methacrylate (hereinafter referred to as acrylates) in products obtained by reacting polyester polyols with isocyanate monomers or prepolymers. It can be easily obtained by reacting an acrylate monomer having a hydroxyl group such as 2-hydroxypropyl acrylate.

  Examples of the UV curable polyester acrylate resin include those that are easily formed when 2-hydroxyethyl acrylate and 2-hydroxy acrylate monomers are generally reacted with polyester polyol.

  Specific examples of UV curable polyol acrylate resins include trimethylolpropane triacrylate, ditrimethylolpropane tetraacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, alkyl-modified dipentaerythritol pentaacrylate, etc. I can list them.

  Specific examples of the photoreaction initiator of these ultraviolet curable resins include benzoin and its derivatives, acetophenone, benzophenone, hydroxybenzophenone, Michler's ketone, α-amyloxime ester, thioxanthone, and derivatives thereof. You may use with a photosensitizer. The photoinitiator can also be used as a photosensitizer. In addition, when using an epoxy acrylate photoinitiator, a sensitizer such as n-butylamine, triethylamine, or tri-n-butylphosphine can be used. The photoreaction initiator or photosensitizer used in the ultraviolet curable resin composition is 0.1 to 15 parts by weight, preferably 1 to 10 parts by weight, based on 100 parts by weight of the composition.

  Examples of the resin monomer include general monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, benzyl acrylate, cyclohexyl acrylate, vinyl acetate, and styrene as monomers having one unsaturated double bond. In addition, monomers having two or more unsaturated double bonds include ethylene glycol diacrylate, propylene glycol diacrylate, divinylbenzene, 1,4-cyclohexane diacrylate, 1,4-cyclohexyldimethyl adiacrylate, and the above-mentioned trimethylolpropane. Examples thereof include triacrylate and pentaerythritol tetraacryl ester.

  Content of the ultraviolet curable resin in a coating composition is the range of 10 mass%-70 mass% as solid content. If it is less than 10% by mass, film thickness unevenness is likely to occur due to drying, and if it exceeds 70% by mass, the viscosity of the coating composition becomes too high and streak-like failures are likely to occur. Especially preferably, it is the range of 20 mass%-50 mass%, and this range is excellent in coating suitability and drying suitability, and it is preferable that a coating failure does not occur easily.

  These actinic ray curable resin layers can be coated by a known method such as a gravure coater, a dip coater, a reverse coater, a wire bar coater, a die coater, or an ink jet method.

As a light source for curing an ultraviolet curable resin by a photocuring reaction to form a cured film layer, any light source that generates ultraviolet rays can be used without any limitation. For example, a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a carbon arc lamp, a metal halide lamp, a xenon lamp, or the like can be used. Irradiation conditions vary depending on each lamp, but the irradiation light amount may be about ²⁰ to 10000 mJ / cm ² , preferably 40 to 2000 mJ / cm ² , and particularly preferably 50 to 500 mJ / cm ² .

  In the present invention, a mixed solvent of water and an organic solvent is used as a solvent for the UV curable resin layer composition coating solution, and the water ratio is 30% by mass or more based on the total solvent contained in the coating composition. Is a feature. The present inventor improves the flatness deterioration phenomenon when a cured resin layer containing a large amount of an organic solvent is applied on a cellulose ester film produced by a melt casting method by increasing the water ratio. This is what we found. The water ratio in the solvent of the coating composition is preferably 30 to 100% by mass, particularly preferably 30% to 80% by mass, further preferably 35% to 75% by mass, and particularly preferably 40%. It is mass%-70 mass%. When the moisture ratio is less than 30% by mass, the effect of improving the flatness of the present invention cannot be obtained, and the range of 30% by mass to 80% by mass is preferable because the applicability is excellent.

  In the present invention, the organic solvent to be mixed with water is not particularly limited. For example, the organic solvent is appropriately selected from hydrocarbons, alcohols, ketones, esters, glycol ethers, and other organic solvents, or these Can be mixed and used.

  A particularly preferable organic solvent is a water-miscible organic solvent. Examples of the water-miscible organic solvent include alcohols (eg, methanol, ethanol, propanol, isopropanol, butanol, isobutanol, secondary butanol, tertiary butanol, pentanol, hexanol, cyclohexanol, benzyl alcohol, etc.), many Monohydric alcohols (for example, ethylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, propylene glycol, dipropylene glycol, polypropylene glycol, butylene glycol, hexanediol, pentanediol, glycerin, hexanetriol, thiodiglycol, etc.), polyvalent Alcohol ethers (eg, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether) , Ethylene glycol monobutyl ether, diethylene glycol monomethyl ether, diethylene glycol monomethyl ether, diethylene glycol monobutyl ether, propylene glycol monomethyl ether, propylene glycol monobutyl ether, ethylene glycol monomethyl ether acetate, triethylene glycol monomethyl ether, triethylene glycol monoethyl ether, ethylene glycol mono Phenyl ether, propylene glycol monophenyl ether, etc.), amines (eg, ethanolamine, diethanolamine, triethanolamine, N-methyldiethanolamine, N-ethyldiethanolamine, morpholine, N-ethylmorpholine, ethylenediamine, diethylenediamine) , Triethylenetetramine, tetraethylenepentamine, polyethyleneimine, pentamethyldiethylenetriamine, tetramethylpropylenediamine, etc.), amides (eg, formamide, N, N-dimethylformamide, N, N-dimethylacetamide, etc.), heterocyclic rings (For example, 2-pyrrolidone, N-methyl-2-pyrrolidone, cyclohexyl pyrrolidone, 2-oxazolidone, 1,3-dimethyl-2-imidazolidinone, etc.), sulfoxides (for example, dimethyl sulfoxide, etc.), sulfones (for example, , Sulfolane, etc.), urea, acetonitrile, acetone and the like. Polyhydric alcohol ethers are particularly preferable in terms of achieving both coating properties and flatness. Among polyhydric alcohol ethers, specifically, cellosolves are preferable, and butyl cellosolve, isopropyl cellosolve, ethyl cellosolve, methyl cellosolve, etc. have appropriate wettability with respect to the object to be coated, and thus show good coating properties. Uniform coating can be formed.

  In the present invention, an oil-based solvent can also be used as appropriate.

  Examples of oil-based solvents include alcohols (eg, pentanol, heptanol, octanol, phenylethyl alcohol, phenylpropyl alcohol, furfuryl alcohol, anil alcohol) in addition to those exemplified as the water-miscible organic solvent. Etc.), esters (ethylene glycol diacetate, ethylene glycol monomethyl ether acetate, diethylene glycol monomethyl ether acetate, propylene glycol diacetate, ethyl acetate, amyl acetate, benzyl acetate, phenylethyl acetate, phenoxyethyl acetate, ethyl ethyl acetate, propionic acid Benzyl, ethyl benzoate, butyl benzoate, butyl laurate, isopropyl myristate, triethyl phosphate, tributyl phosphate, diethyl phthalate, Dibutyl tartrate, diethyl malonate, dipropyl malonate, diethyl diethyl malonate, diethyl succinate, dibutyl succinate, diethyl glutarate, diethyl adipate, dipropyl adipate, dibutyl adipate, di (2-methoxyethyl) adipate , Diethyl sebacate, diethyl maleate, dibutyl maleate, dioctyl maleate, diethyl fumarate, dioctyl fumarate, cinnamate-3-hexenyl, etc.), ethers (for example, butyl phenyl ether, benzyl ethyl ether, hexyl ether) Etc.), ketones (eg benzyl methyl ketone, benzyl acetone, diacetone alcohol, cyclohexanone, etc.), hydrocarbons (eg petroleum ether, petroleum benzyl, tetralin, decalin, tertiary amyl) Benzene, dimethyl naphthalene, etc.), amides (e.g., N, N-diethyldodecanamide, etc.).

  These organic solvents are preferably used in an amount of 5% by mass to 50% by mass, more preferably 10% by mass to 40% by mass, and still more preferably 10% by mass to 30% by mass with respect to the coating composition.

  Further, the UV curable resin layer composition coating solution preferably contains a surfactant, and a cationic, nonionic or anionic surfactant is appropriately selected, and 0.01 to 3% by mass based on the solid content. Is added.

  It is also preferable to add a silicon compound as a surfactant. For example, polyether-modified silicone oil is preferably added. The number average molecular weight of the polyether-modified silicone oil is, for example, 1000 to 100000, preferably 2000 to 50000. If the number average molecular weight is less than 1000, the drying property of the coating film decreases, and conversely, the number average When the molecular weight exceeds 100,000, it tends to be difficult to bleed out to the coating surface.

  Commercially available silicon compounds include DKQ8-779 (trade name, manufactured by Dow Corning), SF3771, SF8410, SF8411, SF8419, SF8421, SF8428, SH200, SH510, SH1107, SH3749, SH3771, BX16-034, SH3746, SH3749, SH8400, SH3771M, SH3772M, SH3773M, SH3775M, BY-16-837, BY-16-839, BY-16-869, BY-16-870, BY-16-004, BY-16-891, BY-16 872, BY-16-874, BY22-008M, BY22-012M, FS-1265 (above, product names manufactured by Toray Dow Corning Silicone), KF-101, KF-100T, KF351, KF3 2, KF353, KF354, KF355, KF615, KF618, KF945, KF6004, Silicone X-22-945, X22-160AS (trade name, manufactured by Shin-Etsu Chemical Co., Ltd.), XF3940, XF3949 (trade name, manufactured by Toshiba Silicone Co., Ltd.) ), Disparon LS-009 (manufactured by Enomoto Kasei Co., Ltd.), Granol 410 (manufactured by Kyoeisha Yushi Chemical Co., Ltd.), TSF4440, TSF4441, TSF4445, TSF4446, TSF4452, TSF4460 (manufactured by GE Toshiba Silicone), BYK-306, BYK- 330, BYK-307, BYK-341, BYK-344, BYK-361 (manufactured by BYK-Japan) L series (for example, L7001, L-7006, L-7604, L-9000) manufactured by Nippon Unicar Co., Ltd. Y Over's, FZ series (FZ-2203, FZ-2206, FZ-2207), and the like.

  These components enhance the applicability to the substrate and the lower layer. When added to the outermost surface layer of the laminate, it not only improves the water repellency, oil repellency and antifouling properties of the coating film, but also exhibits an effect on the scratch resistance of the surface. These components are preferably added in a range of 0.01 to 3% by mass with respect to the solid component in the coating solution.

  As a coating method of the ultraviolet curable resin composition coating solution, the above-described methods can be used. The coating amount is suitably 0.1 to 30 μm, preferably 0.5 to 15 μm, as the wet film thickness. The dry film thickness is 0.1 to 10 μm, preferably 1 to 10 μm.

  The ultraviolet curable resin composition is preferably irradiated with ultraviolet rays during or after coating and drying, and the irradiation time for obtaining the irradiation amount of the active rays is preferably about 0.1 seconds to 5 minutes. 0.1 to 10 seconds is more preferable from the viewpoint of curing efficiency or work efficiency of the functional resin.

  In order to prevent blocking, to improve scratch resistance, or to provide antiglare properties, or to adjust the refractive index, fine particles of an inorganic compound or an organic compound may be added to the cured resin layer thus obtained. I can do it.

  Inorganic fine particles used in the cured resin layer include silicon oxide, titanium oxide, aluminum oxide, zirconium oxide, magnesium oxide, calcium carbonate, calcium carbonate, talc, clay, calcined kaolin, calcined calcium silicate, hydrated calcium silicate, silicic acid Mention may be made of aluminum, magnesium silicate and calcium phosphate. In particular, silicon oxide, titanium oxide, aluminum oxide, zirconium oxide, magnesium oxide and the like are preferably used.

  Organic particles include polymethacrylic acid methyl acrylate resin powder, acrylic styrene resin powder, polymethyl methacrylate resin powder, silicon resin powder, polystyrene resin powder, polycarbonate resin powder, benzoguanamine resin powder, melamine resin powder. Polyolefin resin powder, polyester resin powder, polyamide resin powder, polyimide resin powder, or polyfluoroethylene resin powder can be added to the ultraviolet curable resin composition.

  The average particle diameter of these fine particle powders is preferably 0.005 to 5 μm, and particularly preferably 0.01 to 1 μm. As for the ratio of a ultraviolet curable resin composition and fine particle powder, it is desirable to mix | blend so that it may be 0.1-30 mass parts with respect to 100 mass parts of resin compositions.

  The UV curable resin layer is a clear hard coat layer having a center line average roughness (Ra) defined by JIS B 0601 of 0.001 to 0.1 μm, or an anti-glare layer having Ra of about 0.1 to 1 μm. A layer is preferred. The center line average roughness (Ra) is preferably measured with an optical interference type surface roughness measuring instrument, and can be measured using, for example, RST / PLUS manufactured by WYKO.

<Back coat layer>
You may provide a backcoat layer in the surface on the opposite side to the side which provided the cured resin layer of the optical film of this invention. The back coat layer is applied to prevent blocking, and therefore, it is preferable that fine particles are added to the back coat layer. Alternatively, a back coat layer may be provided in order to correct curl caused by providing a cured resin layer or other layers by coating or CVD. In other words, the degree of curling can be balanced by imparting the property of being rounded with the surface on which the backcoat layer is provided facing inward.

  As fine particles added to the back coat layer, examples of inorganic compounds include silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, calcium carbonate, calcium carbonate, talc, clay, calcined kaolin, calcined calcium silicate, tin oxide, and indium oxide. Zinc oxide, ITO, hydrated calcium silicate, aluminum silicate, magnesium silicate and calcium phosphate. Fine particles containing silicon are preferable in terms of low haze, and silicon dioxide is particularly preferable.

  These fine particles are commercially available under the trade names of, for example, Aerosil R972, R972V, R974, R812, 200, 200V, 300, R202, OX50, and TT600 (manufactured by Nippon Aerosil Co., Ltd.). . Zirconium oxide fine particles are commercially available under the trade names of Aerosil R976 and R811 (manufactured by Nippon Aerosil Co., Ltd.) and can be used. Examples of the polymer include silicone resin, fluorine resin, and acrylic resin. Silicone resins are preferable, and those having a three-dimensional network structure are particularly preferable. For example, Tospearl 103, 105, 108, 120, 145, 3120, and 240 (manufactured by Toshiba Silicone Co., Ltd.) It is marketed by name and can be used.

  Among these, Aerosil 200V and Aerosil R972V are particularly preferably used because they have a large anti-blocking effect while keeping haze low. In the optical film of the present invention, the dynamic friction coefficient on the back surface side of the cured resin layer is preferably 0.9 or less, particularly preferably 0.1 to 0.9.

  The fine particles contained in the backcoat layer are 0.1 to 50% by weight, preferably 0.1 to 10% by weight, based on the binder. When the back coat layer is provided, the increase in haze is preferably 1% or less, more preferably 0.5% or less, and particularly preferably 0.0 to 0.1%.

  Specifically, the back coat layer is formed by applying a composition containing a solvent for dissolving or swelling a cellulose ester film. The solvent used may include a solvent to be dissolved and / or a solvent to be swollen in addition to a solvent to be swelled, a composition in which these are mixed at an appropriate ratio depending on the degree of curling of the transparent resin film and the type of resin, and This is done using the coating amount.

  In order to enhance the curl prevention function, it is effective to increase the mixing ratio of the solvent for dissolving the solvent composition to be used and / or the solvent for swelling, and to decrease the ratio of the solvent not to be dissolved. This mixing ratio is preferably (solvent to be dissolved and / or solvent to be swollen) :( solvent to be dissolved) = 10: 0 to 1: 9. Examples of the solvent for dissolving or swelling the transparent resin film contained in such a mixed composition include dioxane, acetone, methyl ethyl ketone, N, N-dimethylformamide, methyl acetate, ethyl acetate, trichloroethylene, methylene chloride, and ethylene chloride. , Tetrachloroethane, trichloroethane, chloroform and the like. Examples of the solvent that does not dissolve include methanol, ethanol, n-propyl alcohol, i-propyl alcohol, n-butanol, and hydrocarbons (toluene, xylene, cyclohexanol).

  These coating compositions are preferably applied to the surface of the transparent resin film with a gravure coater, dip coater, reverse coater, wire bar coater, die coater, etc., with a wet film thickness of 1 to 100 μm, particularly 5 to 30 μm. Preferably there is. Examples of the resin used as the binder of the backcoat layer include vinyl chloride-vinyl acetate copolymer, vinyl chloride resin, vinyl acetate resin, vinyl acetate-vinyl alcohol copolymer, partially hydrolyzed vinyl chloride-vinyl acetate copolymer. Polymer, vinyl chloride-vinylidene chloride copolymer, vinyl chloride-acrylonitrile copolymer, ethylene-vinyl alcohol copolymer, chlorinated polyvinyl chloride, ethylene-vinyl chloride copolymer, ethylene-vinyl acetate copolymer, etc. Vinyl polymer or copolymer, nitrocellulose, cellulose acetate propionate (preferably acetyl group substitution degree 1.8-2.3, propionyl group substitution degree 0.1-1.0), diacetyl cellulose, cellulose Cellulose derivatives such as acetate butyrate resin, maleic acid and / or Or acrylic acid copolymer, acrylic ester copolymer, acrylonitrile-styrene copolymer, chlorinated polyethylene, acrylonitrile-chlorinated polyethylene-styrene copolymer, methyl methacrylate-butadiene-styrene copolymer, acrylic resin Rubber resins such as polyvinyl acetal resin, polyvinyl butyral resin, polyester polyurethane resin, polyether polyurethane resin, polycarbonate polyurethane resin, polyester resin, polyether resin, polyamide resin, amino resin, styrene-butadiene resin, butadiene-acrylonitrile resin, Examples thereof include, but are not limited to, silicone resins and fluorine resins. For example, as an acrylic resin, Acrypet MD, VH, MF, V (manufactured by Mitsubishi Rayon Co., Ltd.), Hyperl M-4003, M-4005, M-4006, M-4202, M-5000, M-5001, M-4501 (manufactured by Negami Kogyo Co., Ltd.), Dialnal BR-50, BR-52, BR-53, BR-60, BR-64, BR-73, BR-75, BR-77, BR-79, BR -80, BR-82, BR-83, BR-85, BR-87, BR-88, BR-90, BR-93, BR-95, BR-100, BR-101, BR-102, BR-105 BR-106, BR-107, BR-108, BR-112, BR-113, BR-115, BR-116, BR-117, BR-118, etc. (Mitsubishi Rayon Co., Ltd.) acrylic and The methacrylic monomers such as various homopolymers and copolymers were prepared as raw materials are commercially available, can also be selected preferred mono from this appropriate.

  Particularly preferred are cellulose resin layers such as diacetylcellulose and cellulose acetate propionate.

  The order of coating the backcoat layer may be before or after coating the cellulose ester film on the opposite side of the backcoat layer (clear hard coat layer or other layer such as an antistatic layer). When the back coat layer also serves as an anti-blocking layer, it is desirable to coat it first. Alternatively, the backcoat layer can be applied in two or more steps.

  The optical film of the present invention is suitable for uniformly forming a thin film of a metal compound layer by coating or plasma CVD, particularly atmospheric pressure plasma treatment, and these are useful as an antireflection layer.

  As an atmospheric pressure plasma treatment method, for example, an atmospheric pressure plasma discharge treatment method for applying a high-frequency pulse voltage described in JP-A-11-181573, JP-A-2000-26632, JP-A-2002-110397, or the like can be used. Alternatively, the conductive layer can be provided by an atmospheric pressure plasma discharge processing method described in JP-A-2001-337201. Alternatively, the antireflection layer can be provided by the methods described in JP-A No. 2002-228803, Japanese Patent Application No. 2002-369679, Japanese Patent Application No. 2002-317883, and Japanese Patent Application No. 2003-50823. Alternatively, the antifouling layer can be provided by the method described in Japanese Patent Application No. 2003-50823. Alternatively, the antireflection layer can be applied by the method described in JP-A-2003-93963 and Japanese Patent Application No. 2002-49724.

  On the optical film of the present invention, a metal compound (for example, SiOx, SiOxNy, TiOxNy, SiOxCz (x = 1 to 2, y = 0.1 to 1, z = 0.1) is mostly obtained under an atmosphere of nitrogen gas. It is preferable to form a thin film of metal oxide or the like among metal oxides, metal nitrides, metal oxynitrides, metal carbides, etc. The nitrogen gas contained in the gas is 60 to 99.9% by volume, preferably 75 to 99.9% by volume, and more preferably 90 to 99.9% by volume. In addition to nitrogen gas, a rare gas such as argon or helium may be contained, a gas of a metal compound for forming a thin film is contained, and further a gas (addition gas) for promoting a reaction such as oxygen and hydrogen. Or an auxiliary gas). By these, a low refractive index layer, a high refractive index layer, a medium refractive index layer, a transparent conductive layer, an antistatic layer, an antifouling layer and the like containing a metal compound can be formed.

  Next, the antireflection layer formed on these cured resin layers will be described.

(Antireflection layer)
In the present invention, the method for providing the antireflection layer is not particularly limited, and the antireflection layer can be formed by coating, sputtering, vapor deposition, CVD (Chemical Vapor Deposition), or a combination thereof.

  As a method of forming the antireflection layer by coating, a method of dispersing metal oxide powder in a binder resin dissolved in a solvent, coating and drying, a method of using a polymer having a crosslinked structure as a binder resin, ethylenic unsaturated Examples of the method include a method of forming a layer by containing a monomer and a photopolymerization initiator and irradiating actinic rays.

  In the present invention, it is preferable to provide an antireflection layer on an optical film provided with a cured resin layer. A low refractive index layer is formed on the uppermost layer of the optical film, and a metal oxide layer of a high refractive index layer is formed between them. It is preferable to provide a metal oxide layer in which the refractive index is adjusted by changing the content of the product or the ratio to the resin binder and the type of metal to reduce the reflectance. The refractive index of the high refractive index layer is preferably 1.55 to 2.30, and more preferably 1.57 to 2.20. The refractive index of the medium refractive index layer is adjusted so as to be an intermediate value between the refractive index (about 1.5) of the cellulose ester film as the substrate and the refractive index of the high refractive index layer. The refractive index of the middle refractive index layer is preferably 1.55-1.80. The thickness of each layer is preferably 5 nm to 0.5 μm, more preferably 10 nm to 0.3 μm, and most preferably 30 nm to 0.2 μm. The haze of the metal oxide layer is preferably 5% or less, more preferably 3% or less, and most preferably 1% or less. The strength of the metal oxide layer is preferably 3H or more, and most preferably 4H or more, with a pencil hardness of 1 kg. When the metal oxide layer is formed by coating, it is preferable to include inorganic fine particles and a binder polymer.

The inorganic fine particles used for the metal oxide layer such as the middle refractive index layer or the high refractive index layer preferably have a refractive index of 1.80 to 2.80, more preferably 1.90 to 2.80. . The primary particles of the inorganic fine particles preferably have a weight average diameter of 1 to 150 nm, more preferably 1 to 100 nm, and most preferably 1 to 80 nm. The weight average diameter of the inorganic fine particles in the layer is preferably 1 to 200 nm, more preferably 5 to 150 nm, still more preferably 10 to 100 nm, and most preferably 10 to 80 nm. . The average particle diameter of the inorganic fine particles is measured by a light scattering method if it is 20-30 nm or more and by an electron micrograph if it is 20-30 nm or less. The specific surface area of the inorganic fine particles, a measured value by the BET method, is preferably from 10 to 400 m ² / g, more preferably from 20 to 200 m ² / g, a 30 to 150 m ² / g Is most preferred.

  The inorganic fine particles are particles formed from a metal oxide. Examples of metal oxides or sulfides include titanium dioxide (eg, rutile, rutile / anatase mixed crystal, anatase, amorphous structure), tin oxide, indium oxide, ITO, zinc oxide, zirconium oxide, and the like. Of these, titanium dioxide, tin oxide, and indium oxide are particularly preferable. The inorganic fine particles are mainly composed of oxides of these metals and can further contain other elements. The main component means a component having the largest content (mass%) among the components constituting the particles. Examples of other elements include Ti, Zr, Sn, Sb, Cu, Fe, Mn, Pb, Cd, As, Cr, Hg, Zn, Al, Mg, Si, P, and S.

  The inorganic fine particles may be surface-treated. The surface treatment can be performed using an inorganic compound or an organic compound. Examples of inorganic compounds used for the surface treatment include alumina, silica, zirconium oxide and iron oxide. Of these, alumina and silica are preferable. Examples of the organic compound used for the surface treatment include polyols, alkanolamines, stearic acid, silane coupling agents, and titanate coupling agents. Of these, a silane coupling agent is most preferable. It may be processed by combining two or more types of surface treatments.

  The shape of the inorganic fine particles is preferably a rice grain shape, a spherical shape, a cubic shape, a layer shape, a spindle shape, or an indefinite shape. Two or more kinds of inorganic fine particles may be used in combination in the metal oxide layer.

  The proportion of the inorganic fine particles in the metal oxide layer is preferably 5 to 90% by volume, more preferably 10 to 65% by volume, and still more preferably 20 to 55% by volume.

  The inorganic fine particles are supplied to a coating liquid for forming a metal oxide layer in a dispersion state dispersed in a medium. As the dispersion medium for the inorganic fine particles, a liquid having a boiling point of 60 to 170 ° C. is preferably used. Specific examples of the dispersion solvent include water, alcohol (eg, methanol, ethanol, isopropanol, butanol, benzyl alcohol), ketone (eg, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone), ester (eg, methyl acetate, ethyl acetate). , Propyl acetate, butyl acetate, methyl formate, ethyl formate, propyl formate, butyl formate), aliphatic hydrocarbons (eg, hexane, cyclohexane), aromatic hydrocarbons (eg, benzene, toluene, xylene), amides (eg, Examples include dimethylformamide, dimethylacetamide, n-methylpyrrolidone), ether (eg, diethyl ether, dioxane, tetrahydrofuran), and ether alcohol (eg, 1-methoxy-2-propanol). Of these, toluene, xylene, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone and butanol are particularly preferable.

  The inorganic fine particles can be dispersed in the medium using a disperser. Examples of the disperser include a sand grinder mill (eg, a bead mill with pins), a high-speed impeller mill, a pebble mill, a roller mill, an attritor, and a colloid mill. A sand grinder mill and a high-speed impeller mill are particularly preferred. Further, preliminary dispersion processing may be performed. Examples of the disperser used for the preliminary dispersion treatment include a ball mill, a three-roll mill, a kneader, and an extruder.

  The metal oxide layer preferably uses a polymer having a crosslinked structure (hereinafter also referred to as “crosslinked polymer”) as a binder polymer. Examples of the crosslinked polymer include polymers having a saturated hydrocarbon chain such as polyolefin (hereinafter collectively referred to as “polyolefin”), crosslinked products such as polyether, polyurea, polyurethane, polyester, polyamine, polyamide and melamine resin. Among them, a crosslinked product of polyolefin, polyether and polyurethane is preferred, a crosslinked product of polyolefin and polyether is more preferred, and a crosslinked product of polyolefin is most preferred. Moreover, it is more preferable that the crosslinked polymer has an anionic group. The anionic group has a function of maintaining the dispersion state of the inorganic fine particles, and the crosslinked structure has a function of imparting a film forming ability to the polymer and strengthening the film. The anionic group may be directly bonded to the polymer chain or may be bonded to the polymer chain via a linking group, but is bonded to the main chain as a side chain via the linking group. Is preferred.

  The refractive index of the low refractive index layer used in the antireflective layer of the present invention is preferably 1.46 or less, and particularly preferably 1.3 to 1.45, by silicon alkoxide as a coating composition by a sol-gel method. A low refractive index layer can be formed. Alternatively, a low refractive index layer can be formed using a fluorine resin. In particular, it is preferably composed of a cured product of a thermosetting or ionizing radiation curable fluorine-containing resin and ultrafine particles of silicon oxide. The silicon oxide ultrafine particles may be composite particles having porous particles described later and a coating layer provided on the surface of the porous particles, or hollow particles filled with a solvent, gas, or porous substance inside. preferable.

  The dynamic friction coefficient of the cured product is preferably 0.02 to 0.2, and the pure water contact angle is preferably 90 to 130 °. Examples of the curable fluorine-containing resin include perfluoroalkyl group-containing silane compounds (for example, (heptadecafluoro-1,1,2,2-tetradecyl) triethoxysilane) and fluorine-containing copolymers (crosslinkable groups). Monomer and fluorine-containing monomer as structural units). Specific examples of the fluorine-containing monomer unit include, for example, hexafluoroethylene, hexafluoropropylene, tetrafluoroethylene, and fluoroolefins (for example, vinylidene fluoride perfluoro-2,2-dimethyl-1,3-dioxole, fluoroethylene, etc.) Fluorinated alkyl ester derivatives of (meth) acrylic acid (for example, Biscoat 6FM (manufactured by Osaka Organic Chemical Co., Ltd.) and M-2020 (manufactured by Daikin)), fluorinated vinyl ethers, and the like. As a monomer having a crosslinkable group, a (meth) acrylate monomer having a crosslinkable functional group in the molecule in advance such as glycidyl methacrylate, and a (meth) acrylate having a carboxyl group, an amino group, a hydroxyl group, a sulfonic acid group, etc. And monomers (for example, (meth) acrylic acid, methylol (meth) acrylate, hydroxyalkyl (meth) acrylate, allyl acrylate, etc.). It is described in JP-A-10-25388 and JP-A-10-147739 that a crosslinked structure can be introduced after copolymerization.

  Further, not only a polymer having the above-mentioned fluorine-containing monomer as a structural unit but also a copolymer with a monomer not containing a fluorine atom can be used. There are no particular limitations on the monomer units that can be used in combination, for example, acrylic esters (methyl acrylate, methyl acrylate, ethyl acrylate, 2-ethylhexyl acrylate), methacrylate esters (methyl methacrylate, ethyl methacrylate, Butyl methacrylate, ethylene glycol dimethacrylate, etc.), styrene derivatives (styrene, divinylbenzene, α-methylstyrene, vinyltoluene, etc.), acrylamides (N-tertbutylacrylamide, N-cyclohexylacrylamide, etc.), methacrylamides, acrylonitrile Derivatives, olefins (ethylene, propylene, isoprene, vinylidene chloride, vinyl chloride, etc.), vinyl ethers (methyl vinyl ether, etc.), vinyl esters (vinyl acetate, propionic acid) Alkenyl, vinyl cinnamate) may be mentioned.

  It is preferable to add silicon oxide fine particles to the fluorine-containing resin used for forming the low refractive index layer in order to improve scratch resistance. The addition amount is adjusted in consideration of the refractive index and scratch resistance. As the silicon oxide fine particles, silica sol dispersed in a commercially available organic solvent can be added to the coating composition as it is, or various commercially available silica powders can be dispersed in an organic solvent and used.

  Composite particles having porous particles and a coating layer provided on the surface of the porous particles, or hollow particles filled with a solvent, gas, or porous substance, which are particularly preferably used in the low refractive index layer of the present invention Will be described.

  The inorganic fine particle is (I) a composite particle comprising a porous particle and a coating layer provided on the surface of the porous particle, or (II) a cavity inside, and the content is a solvent, gas or porous substance It is a hollow particle filled with. The low refractive index layer may contain either (I) composite particles or (II) hollow particles, or may contain both.

  The hollow particles are particles having cavities inside, and the cavities are surrounded by particle walls. The cavity is filled with a content such as a solvent, a gas, or a porous material used at the time of preparation. It is desirable that the average particle diameter of such inorganic fine particles is in the range of 5 to 300 nm, preferably 10 to 200 nm. The inorganic fine particles used are appropriately selected according to the thickness of the transparent film to be formed, and may be in the range of 2/3 to 1/10 of the film thickness of the transparent film such as the low refractive index layer to be formed. desirable. These inorganic fine particles are preferably used in a state of being dispersed in an appropriate medium in order to form a low refractive index layer. As the dispersion medium, water, alcohol (for example, methanol, ethanol, isopropyl alcohol), ketone (for example, methyl ethyl ketone, methyl isobutyl ketone), and ketone alcohol (for example, diacetone alcohol) are preferable.

  The thickness of the coating layer of the composite particles or the thickness of the particle walls of the hollow particles is desirably in the range of 1 to 20 nm, preferably 2 to 15 nm. In the case of composite particles, if the thickness of the coating layer is less than 1 nm, the particles may not be completely covered, and silicate monomers and oligomers with a low degree of polymerization, which are coating liquid components described later, are easy. In some cases, the inside of the composite particle enters the inside and the porosity of the inside is reduced, so that the effect of the low refractive index cannot be sufficiently obtained. When the thickness of the coating layer exceeds 20 nm, the silicic acid monomer and oligomer do not enter the inside, but the porosity (pore volume) of the composite particles is lowered and the effect of low refractive index is sufficiently obtained. It may not be possible. In the case of hollow particles, if the particle wall thickness is less than 1 nm, the particle shape may not be maintained, and even if the thickness exceeds 20 nm, the effect of low refractive index may not be sufficiently exhibited. is there.

The coating layer of the composite particles or the particle wall of the hollow particles is preferably composed mainly of silica. The coating layer of the composite particle or the particle wall of the hollow particle may contain a component other than silica, specifically, Al ₂ O ₃ , B ₂ O ₃ , TiO ₂ , ZrO ₂ , SnO _2. and _{CeO 2, P 2 O 3,} Sb 2 O 3, MoO 3, ZnO 2, WO 3 and the like. Examples of the porous particles constituting the composite particles include those made of silica, those made of silica and an inorganic compound other than silica, and those made of CaF ₂ , NaF, NaAlF ₆ , MgF, and the like. Among these, porous particles made of a composite oxide of silica and an inorganic compound other than silica are particularly preferable. Examples of inorganic compounds other than silica include Al ₂ O ₃ , B ₂ O ₃ , TiO ₂ , ZrO ₂ , SnO ₂ , CeO ₂ , P ₂ O ₃ , Sb ₂ O ₃ , MoO ₃ , ZnO ₂ , WO _{3 and the} like. 1 type or 2 types or more can be mentioned. In such a porous particle, the molar ratio MOX / SiO ₂ when the silica is represented by SiO ₂ and the inorganic compound other than silica is represented by oxide (MOX) is 0.0001 to 1.0, preferably It is desirable to be in the range of 0.001 to 0.3. It is difficult to obtain porous particles having a molar ratio MOX / SiO ₂ of less than 0.0001, and even if obtained, those having a lower refractive index are not obtained. On the other hand, if the molar ratio MOX / SiO _{2 of} the porous particles exceeds 1.0, the ratio of silica decreases, so that particles having a small pore volume and a low refractive index may not be obtained.

  The pore volume of such porous particles is desirably in the range of 0.1 to 1.5 ml / g, preferably 0.2 to 1.5 ml / g. If the pore volume is less than 0.1 ml / g, particles having a sufficiently reduced refractive index cannot be obtained. If the pore volume exceeds 1.5 ml / g, the strength of the fine particles is lowered, and the strength of the resulting coating may be lowered. is there.

  Incidentally, the pore volume of such porous particles can be obtained by a mercury intrusion method. Examples of the contents of the hollow particles include a solvent, a gas, and a porous material used at the time of preparing the particles. The solvent may contain an unreacted particle precursor used in preparing the hollow particles, the catalyst used, and the like. Moreover, what consists of the compound illustrated by the said porous particle as a porous substance is mentioned. These contents may be composed of a single component or may be a mixture of a plurality of components.

  As a method for producing such inorganic fine particles, for example, the method for preparing composite oxide colloidal particles disclosed in paragraphs [0010] to [0033] of JP-A-7-133105 is suitably employed. Specifically, when the composite particles are composed of silica and an inorganic compound other than silica, the inorganic compound particles are produced from the following first to third steps.

First Step: Preparation of Porous Particle Precursor In the first step, an alkali aqueous solution of a silica raw material and an inorganic compound raw material other than silica is separately prepared in advance, or a silica raw material and an inorganic compound raw material other than silica are prepared in advance. A mixed aqueous solution is prepared, and this aqueous solution is gradually added to an aqueous alkaline solution having a pH of 10 or more while stirring according to the composite ratio of the target composite oxide to prepare a porous particle precursor.

  As the silica raw material, alkali metal, ammonium or organic base silicate is used. Sodium silicate (water glass) or potassium silicate is used as the alkali metal silicate. Examples of the organic base include quaternary ammonium salts such as tetraethylammonium salt, and amines such as monoethanolamine, diethanolamine, and triethanolamine. The ammonium silicate or the organic base silicate includes an alkaline solution obtained by adding ammonia, a quaternary ammonium hydroxide, an amine compound or the like to a silicic acid solution.

  In addition, alkali-soluble inorganic compounds are used as raw materials for inorganic compounds other than silica. Specifically, an oxo acid of an element selected from Al, B, Ti, Zr, Sn, Ce, P, Sb, Mo, Zn, W, etc., an alkali metal salt or alkaline earth metal salt of the oxo acid, ammonium Salts and quaternary ammonium salts. More specifically, sodium aluminate, sodium tetraborate, zirconyl ammonium carbonate, potassium antimonate, potassium stannate, sodium aluminosilicate, sodium molybdate, cerium ammonium nitrate, and sodium phosphate are suitable.

Although the pH value of the mixed aqueous solution changes simultaneously with the addition of these aqueous solutions, an operation for controlling the pH value within a predetermined range is not particularly required. The aqueous solution finally has a pH value determined by the type of inorganic oxide and the mixing ratio thereof. There is no restriction | limiting in particular in the addition rate of the aqueous solution at this time. Further, in the production of composite oxide particles, a dispersion of seed particles can be used as a starting material. The seed particles are not particularly limited, but inorganic oxides such as SiO ₂ , Al ₂ O ₃ , TiO ₂ or ZrO ₂ or fine particles of these composite oxides are used. Usually, these sols are used. I can do it. Furthermore, the porous particle precursor dispersion obtained by the above production method may be used as a seed particle dispersion. When the seed particle dispersion is used, the pH of the seed particle dispersion is adjusted to 10 or more, and then the aqueous solution of the compound is added to the above-described alkaline aqueous solution while stirring. Also in this case, it is not always necessary to control the pH of the dispersion. In this way, when seed particles are used, it is easy to control the particle size of the porous particles to be prepared, and particles having a uniform particle size can be obtained.

  The silica raw material and the inorganic compound raw material described above have high solubility on the alkali side. However, when both are mixed in this highly soluble pH region, the solubility of oxo acid ions such as silicate ions and aluminate ions decreases, and these composites precipitate and grow into fine particles, or seed particles. Particle deposition occurs on the top. Therefore, it is not always necessary to perform pH control as in the conventional method for precipitation and growth of fine particles.

The composite ratio of silica and inorganic compound other than silica in the first step is that the inorganic compound relative to silica is converted to oxide (MOx), and the molar ratio of MOx / SiO ₂ is 0.05 to 2.0, preferably It is desirable to be within the range of 0.2 to 2.0. Within this range, the pore volume of the porous particles increases as the proportion of silica decreases. However, even when the molar ratio exceeds 2.0, the pore volume of the porous particles hardly increases. On the other hand, when the molar ratio is less than 0.05, the pore volume becomes small. When preparing hollow particles, the molar ratio of MOx / SiO ₂ is preferably in the range of 0.25 to 2.0.

Second step: Removal of inorganic compound other than silica from porous particles In the second step, inorganic compounds other than silica (elements other than silicon and oxygen) are obtained from the porous particle precursor obtained in the first step. At least a portion is selectively removed. As a specific removal method, the inorganic compound in the porous particle precursor is dissolved and removed using a mineral acid or an organic acid, or is contacted with a cation exchange resin for ion exchange removal.

  The porous particle precursor obtained in the first step is a particle having a network structure in which silicon and an inorganic compound constituent element are bonded via oxygen. By removing the inorganic compound (elements other than silicon and oxygen) from the porous particle precursor in this way, porous particles having a larger porosity and a larger pore volume can be obtained. Further, if the amount of removing the inorganic oxide (elements other than silicon and oxygen) from the porous particle precursor is increased, the hollow particles can be prepared.

  In addition, prior to removing inorganic compounds other than silica from the porous particle precursor, a silicic acid solution obtained by removing the alkali metal salt of silica from the porous particle precursor dispersion obtained in the first step. Alternatively, it is preferable to form a silica protective film by adding a hydrolyzable organosilicon compound. The thickness of the silica protective film may be 0.5 to 15 nm. Even if the silica protective film is formed, the protective film in this step is porous and thin, so that it is possible to remove inorganic compounds other than silica described above from the porous particle precursor.

  By forming such a silica protective film, inorganic compounds other than the silica described above can be removed from the porous particle precursor while maintaining the particle shape. Further, when forming the silica coating layer described later, the pores of the porous particles are not blocked by the coating layer, and therefore the silica coating layer described later is formed without reducing the pore volume. I can do it. Note that when the amount of the inorganic compound to be removed is small, the particles are not broken, and thus it is not always necessary to form a protective film.

  When preparing hollow particles, it is desirable to form this silica protective film. When preparing the hollow particles, the inorganic compound is removed to obtain a hollow particle precursor composed of a silica protective film, a solvent in the silica protective film, and an undissolved porous solid content. When a coating layer to be described later is formed on the precursor, the formed coating layer becomes a particle wall to form hollow particles.

  The amount of the silica source added for forming the silica protective film is preferably small as long as the particle shape can be maintained. If the amount of the silica source is too large, the silica protective film becomes too thick, and it may be difficult to remove inorganic compounds other than silica from the porous particle precursor. The hydrolyzable organosilicon compound used for forming the silica protective film includes a general formula RnSi (OR ′) 4-n [R, R ′: hydrocarbon such as alkyl group, aryl group, vinyl group, acrylic group, etc. An alkoxysilane represented by the group, n = 0, 1, 2, or 3] can be used. In particular, tetraalkoxysilanes such as tetramethoxysilane, tetraethoxysilane, and tetraisopropoxysilane are preferably used.

  As an addition method, a solution obtained by adding a small amount of alkali or acid as a catalyst to a mixed solution of these alkoxysilane, pure water, and alcohol is added to the dispersion of the porous particles, and the alkoxysilane is hydrolyzed. The produced silicic acid polymer is deposited on the surface of the inorganic oxide particles. At this time, alkoxysilane, alcohol, and catalyst may be simultaneously added to the dispersion. As the alkali catalyst, ammonia, an alkali metal hydroxide, or an amine can be used. As the acid catalyst, various inorganic acids and organic acids can be used.

  When the dispersion medium of the porous particle precursor is water alone or when the ratio of water to the organic solvent is high, a silica protective film can be formed using a silicic acid solution. When a silicic acid solution is used, a predetermined amount of the silicic acid solution is added to the dispersion, and at the same time an alkali is added to deposit the silicic acid solution on the surface of the porous particles. In addition, you may produce a silica protective film together using a silicic acid liquid and the said alkoxysilane.

Third Step: Formation of Silica Coating Layer In the third step, a hydrolyzable organosilicon compound or silicic acid solution is added to the porous particle dispersion prepared in the second step (in the case of hollow particles, a hollow particle precursor dispersion). Etc. is added to coat the surface of the particles with a polymer such as a hydrolyzable organosilicon compound or silicic acid solution to form a silica coating layer.

  Examples of the hydrolyzable organosilicon compound used for forming the silica coating layer include the general formula RnSi (OR ′) 4-n [R, R ′: alkyl group, aryl group, vinyl group, acrylic group as described above. Etc., and alkoxysilanes represented by n = 0, 1, 2, or 3] can be used. In particular, tetraalkoxysilanes such as tetramethoxysilane, tetraethoxysilane, and tetraisopropoxysilane are preferably used.

  As an addition method, a solution obtained by adding a small amount of alkali or acid as a catalyst to a mixed solution of these alkoxysilane, pure water, and alcohol is used as a dispersion of the porous particles (in the case of hollow particles, a hollow particle precursor). In addition, the silicic acid polymer produced by hydrolyzing alkoxysilane is deposited on the surface of the porous particles (in the case of hollow particles, hollow particle precursors). At this time, alkoxysilane, alcohol, and catalyst may be simultaneously added to the dispersion. As the alkali catalyst, ammonia, an alkali metal hydroxide, or an amine can be used. As the acid catalyst, various inorganic acids and organic acids can be used.

  When the dispersion medium of porous particles (in the case of hollow particles, the hollow particle precursor) is water alone or a mixed solvent with an organic solvent and the mixed solvent has a high ratio of water to the organic solvent, a silicate solution You may form a coating layer using. The silicic acid solution is an aqueous solution of a low silicic acid polymer obtained by dealkalizing an aqueous solution of an alkali metal silicate such as water glass by ion exchange treatment.

  The silicic acid solution is added to the dispersion of porous particles (in the case of hollow particles, hollow particle precursors), and at the same time, alkali is added to make the low-silicic acid polymer into porous particles (in the case of hollow particles, hollow particle precursors). ) Deposit on the surface. A silicic acid solution may be used in combination with the alkoxysilane for forming a coating layer. The addition amount of the organosilicon compound or silicic acid solution used for forming the coating layer only needs to be sufficient to cover the surface of the colloidal particles, and the finally obtained silica coating layer has a thickness of 1 to 20 nm. In such an amount, it is added in a dispersion of porous particles (in the case of hollow particles, hollow particle precursor) in a dispersion. When the silica protective film is formed, the organosilicon compound or the silicate solution is added in such an amount that the total thickness of the silica protective film and the silica coating layer is in the range of 1 to 20 nm.

  Next, the dispersion liquid of the particles on which the coating layer is formed is heat-treated. By the heat treatment, in the case of porous particles, the silica coating layer covering the surface of the porous particles is densified, and a dispersion of composite particles in which the porous particles are coated with the silica coating layer is obtained. In the case of a hollow particle precursor, the formed coating layer is densified to form hollow particle walls, and a dispersion of hollow particles having cavities filled with a solvent, gas, or porous solid content is obtained.

  The heat treatment temperature at this time is not particularly limited as long as it can close the fine pores of the silica coating layer, and is preferably in the range of 80 to 300 ° C. When the heat treatment temperature is less than 80 ° C., the fine pores of the silica coating layer may not be completely closed and densified, and the treatment time may take a long time. Further, when the heat treatment temperature exceeds 300 ° C. for a long time, fine particles may be formed, and the effect of low refractive index may not be obtained.

  The refractive index of the inorganic fine particles thus obtained is as low as less than 1.44. Such inorganic fine particles are presumed to have a low refractive index because the porosity inside the porous particles is maintained or the inside is hollow.

  The coating composition for forming the low refractive index layer of the antireflection film coated on the optical film of the present invention preferably contains mainly a low boiling point solvent. Specifically, the solvent having a boiling point of 100 ° C. or less is preferably 50% by mass or more of the total solvent. As a result, even when coated on the surface of a substrate having irregularities such as an antiglare layer, it can be dried quickly, fine film thickness unevenness due to the flow of the coating liquid is reduced, and an increase in reflectance is suppressed. The Moreover, since the drying nonuniformity and white turbidity nonuniformity are suppressed when the solvent whose boiling point is 100 degreeC or more is contained, it is preferable that the solvent whose boiling point is 100 degreeC or more contains 0.1-50 mass%.

  Low boiling point solvents used in coating compositions for the low refractive index layer include ketones such as acetone and methyl ethyl ketone, esters such as methyl acetate and ethyl acetate, ether alcohols such as methyl cellosolve, methanol, ethanol, and isopropanol. Among these alcohols, those having high solubility of the solid content contained in the coating composition are preferably used. Coating solvents having a boiling point exceeding 100 ° C. include ketones such as cyclohexanone, cyclopentanone and methyl-isobutyl ketone, ether alcohols such as diacetone alcohol and propylene glycol monomethyl ether, and alcohols such as 1-butanol and 2-butanol. Etc. are used.

  Each layer of the antireflection film can be formed by coating by 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, a micro gravure coating method or an extrusion coating method. I can do it.

  In the present invention, a method of forming a metal oxide layer by plasma discharge treatment can also be preferably used.

  Hereinafter, a method for forming a metal oxide layer by plasma discharge treatment will be described with reference to FIGS.

  Plasma discharge treatment under atmospheric pressure or a pressure in the vicinity thereof as a method for forming a metal oxide layer on the optical film of the present invention is performed by using a plasma discharge treatment apparatus as described below.

  FIG. 1 is a diagram showing an example of a plasma discharge treatment apparatus used for forming a metal oxide layer on the optical film of the present invention.

  In FIG. 1, this apparatus has a pair of rotating electrodes 10A and 10B. A power supply 80 to which a voltage for generating plasma discharge can be applied is connected to the rotating electrodes 10A and 10B. Connected to ground, 82 is connected to ground.

  The rotating electrodes 10A and 10B are transported while winding an optical film, and are preferably roll electrodes or belt-like electrodes, and FIG. 1 shows the roll electrodes.

  A gap (electrode gap) between these rotating electrodes is a place where electric discharge is performed, and is set to an interval at which the optical film F can be conveyed. The gap between the electrodes becomes the discharge part 50.

  The gap between the electrodes is maintained at atmospheric pressure or a pressure near atmospheric pressure, and the reaction gas G is supplied from the reaction gas supply unit 30 to the plasma film on the surface of the optical film F.

  Here, the optical film F unwound from the original winding roll or the optical film F conveyed from the previous step is first transferred through the guide roll 20 while being in contact with the rotating electrode 10A rotating in the transfer direction, and the discharge unit Through 50, a thin film is formed on the surface of the optical film F.

  The optical film F that has once exited from the discharge unit 50 is U-turned by the U-turn rolls 11A to 11D, and this time, the optical film F is transferred while being in contact with the rotating electrode 10B rotating in the opposite direction to the rotating electrode 10A. After passing through the discharge part 50 again, the surface of the optical film F on which the thin film has been formed is further subjected to plasma discharge treatment to form a thin film. The U-turn is usually performed in about 0.1 seconds to 1 minute.

  The reaction gas G used for the treatment is discharged from the gas discharge port 40 as exhaust gas G ′ after the reaction. It is preferable that the reaction gas G is heated to room temperature to 250 ° C., preferably 50 to 150 ° C., more preferably 80 to 120 ° C., and then fed into the discharge part 50.

  In addition, it is preferable that the discharge part 50 is provided with the rectification | straightening board 51, and while making the flow of the reaction gas G and waste gas G 'smooth, the discharge part 50 spreads and unnecessary discharge is made between electrodes 10A and 10B. The rectifying plate 51 is preferably made of an insulating member.

  In the figure, the thin film formed on the optical film F is omitted. The optical film F having a thin film formed on the surface is conveyed in the direction of the next process or a take-up roll (not shown) via the guide roller 21.

  Accordingly, the optical film F is subjected to plasma discharge treatment by reciprocating the discharge part 50 in a state of being in close contact with the rotary electrodes 10A and 10B.

  Although not shown in the drawing, the devices such as the rotating electrodes 10A and 10B, the guide rolls 20 and 21, the U-turn rolls 11A to 11D, the reactive gas supply unit 30, and the gas discharge port 40 are in a plasma discharge processing vessel that is shielded from the outside. It is preferable that it is enclosed and enclosed.

  Although not shown, a temperature control medium for controlling the temperature of the rotating electrodes 10A and 10B is circulated as necessary to control each electrode surface temperature to a predetermined value. . The diameters of the rotating electrodes 10A and 10B are 10 to 1000 mm, preferably 50 to 500 mm, and those having different diameters may be used in combination.

  FIG. 2 is a view showing an example of a plasma discharge treatment apparatus having a rotating electrode and a fixed electrode useful for forming a metal oxide thin film layer on the hard coat film of the present invention.

  A rotating electrode 110 and a plurality of fixed electrodes 111 arranged opposite to the rotating electrode 110, and an optical film F conveyed from a not-shown original winding roll or a previous process passes through a guide roll 120 and a nip roll 122, and the rotating electrode 110. The optical film F is transferred in synchronization with the rotation of the rotating electrode 110 while being in contact with the rotating electrode 110, and is prepared by the reaction gas generator 131 to the discharge unit 150 under atmospheric pressure or a pressure in the vicinity thereof. The reactive gas G is supplied from the supply pipe 130, and a thin film is formed on the optical film surface facing the fixed electrode 111.

  A power source 180 capable of applying a voltage for generating plasma discharge is connected to the voltage supply means 181 between the rotating electrode 110 and the fixed electrode, one of which is connected to the ground, and 182 is connected to the ground.

  Further, the rotating electrode 110, the fixed electrode 111, and the discharge unit 150 are covered with a plasma discharge processing vessel 190 and are shielded from the outside. The treated exhaust gas G ′ is discharged from a gas exhaust port 140 at the lower part of the processing chamber.

  The optical film F subjected to the plasma discharge treatment is conveyed to the next process or a winding roll (not shown) through the nip roll 123 and the guide roll 121.

  The optical film F is provided with partition plates 124 and 125 to the outside at the nip rolls 122 and 123 at the entrance and exit of the plasma discharge processing vessel, and blocks the air accompanying the optical film F from the outside together with the nip roll 122. In addition, at the outlet, the reaction gas G or the exhaust gas G ′ is prevented from leaking to the outside. Although not shown, the rotating electrode 110 and the fixed electrode 111 are provided for temperature adjustment as necessary. A temperature-controlled medium is circulated inside.

  Thus, in the present invention, the optical film on which the thin film is formed is preferably subjected to plasma discharge treatment while being transferred on the rotating electrode.

  The surface where the rotating electrode is in contact with the optical film is required to have high smoothness, and the surface roughness of the surface of the rotating electrode is the maximum surface roughness (Rmax) specified by JIS-B-0601 is 10 μm or less. Is more preferably 8 μm or less, and particularly preferably 7 μm or less. In addition, it is necessary to prevent dust and foreign matter from adhering to the electrodes for uniform film formation.

The surface of the electrode used for the plasma discharge treatment is preferably coated with a solid dielectric, and in particular, a conductive base material such as a metal is preferably coated with the solid dielectric. Examples of the solid dielectric include plastics such as polytetrafluoroethylene and polyethylene terephthalate, metal oxides such as glass, silicon dioxide, aluminum oxide (Al ₂ O ₃ ), zirconium oxide (ZrO ₂ ), and titanium oxide (TiO ₂ ). Examples thereof include double oxides such as barium titanate.

  It is particularly preferable that the dielectric material is a ceramic-coated dielectric that has been thermally sprayed with ceramics and then sealed with an inorganic material. Here, examples of the conductive base material such as metal include metals such as silver, platinum, stainless steel, aluminum, and iron. Stainless steel is preferable from the viewpoint of processing.

  As the lining material, silicate glass, borate glass, phosphate glass, germanate glass, tellurite glass, aluminate glass, vanadate glass and the like are preferably used. However, among these, borate glass is more preferably used because it is easy to process.

  The electrode used for the plasma discharge treatment can be heated or cooled as necessary from the back side (inside). In the case where the electrode is a belt, it can be cooled with gas from the back side, but it is preferable to control the temperature of the electrode surface and the temperature of the optical film by supplying a medium inside the rotating electrode using a roll.

  As the medium, an insulating material such as distilled water, oil, particularly silicon oil is preferably used.

  The temperature of the optical film during the discharge treatment varies depending on the treatment conditions, but is preferably room temperature to 200 ° C or less, more preferably room temperature to 120 ° C or less, and further preferably 50 to 110 ° C.

  In addition, the curling may be caused by the discharge due to the rise of the film surface temperature or the like, but according to the present invention, the curling can be remarkably generated.

  It is desirable to prevent temperature unevenness particularly in the width direction of the optical film surface during the discharge treatment, preferably within ± 5 ° C., more preferably within ± 1 ° C., particularly preferably ± Within 0.1 ° C.

  In the present invention, the electrode gap is determined in consideration of the thickness of the solid dielectric, the applied voltage and frequency, the purpose of using plasma, and the like. The shortest distance between the solid dielectric and the electrode when a solid dielectric is placed on one of the electrodes, and the distance between the solid dielectrics when a solid dielectric is placed on both of the electrodes is uniform in any case From the viewpoint of generating discharge plasma, 0.5 mm to 20 mm is preferable, and 1 mm ± 0.5 mm is particularly preferable.

  In the present invention, the flow rate of the mixed gas generated by the gas generator is controlled in the discharge portion of the electrode gap and introduced into the plasma discharge portion from the reaction gas supply port. The concentration and flow rate of the reaction gas are appropriately adjusted, but it is preferable to supply the processing gas to the electrode gap at a speed sufficient for the conveyance speed of the optical film. In the discharge section, it is desirable to set the flow rate and discharge conditions so that most of the supplied reaction gas reacts and is used for thin film formation.

  In order to prevent the atmosphere from being mixed into the discharge part and the reaction gas from leaking out of the apparatus, it is preferable that the electrode and the optical film being transferred are surrounded and shielded from the outside. In the present invention, the atmospheric pressure of the discharge part is maintained at atmospheric pressure or a pressure in the vicinity thereof. In addition, the reaction gas may be decomposed in the gas phase to generate metal oxide fine powder, and it is desirable to set the flow rate and discharge conditions so as to reduce the generation.

  Here, the vicinity of atmospheric pressure represents a pressure of 20 to 200 kPa, but 93 to 110 kPa is preferable in order to preferably obtain the effects described in the present invention. The discharge part is preferably slightly positive with respect to the atmospheric pressure outside the apparatus, more preferably atmospheric pressure outside the plasma apparatus +0.1 kPa to 5 kPa.

  In the plasma discharge treatment apparatus useful for the present invention, it is preferable that one electrode is connected to a power source to apply a voltage, and the other electrode is grounded to generate a discharge plasma to generate a stable plasma. .

  The value of the voltage applied to the electrode from the high frequency power source used in the present invention is appropriately determined. For example, the voltage is about 0.5 to 10 kV, the applied frequency is adjusted to 1 kHz to 150 MHz, and the waveform is a pulse wave. Or a sine wave. In particular, it is preferable to apply a high frequency of more than 100 kHz and 50 MHz or less because a preferable discharge part (discharge space) is obtained. Alternatively, a method of simultaneously applying high-frequency voltages having two frequencies of 1 kHz to 200 kHz and 800 kHz to 150 MHz is also preferably used.

Preferably the discharge density in the discharge portion are 5~1000W · min / m ^2, in particular it is desirable that 50~500W · min / m ^2.

  It is desirable that the plasma discharge processing unit is appropriately surrounded by a processing container made of Pyrex (registered trademark) glass or the like, and it is also possible to use metal if insulation from the electrode can be obtained. For example, polyimide resin or the like may be affixed to the inner surface of an aluminum or stainless steel frame, and the metal frame may be subjected to ceramic spraying to achieve insulation. In addition, the reaction gas and the exhaust gas can be appropriately supplied to the discharge unit or exhausted by surrounding the discharge unit, the side surface of the rotating electrode, the side surface of the cellulose ester film transport unit and the like.

  The reaction gas used in the method for forming a metal oxide thin film layer of the present invention will be described.

  The reaction gas for forming the thin film layer preferably contains nitrogen or a rare gas.

  That is, the reactive gas is preferably a mixed gas of nitrogen or a rare gas and a reactive gas described later.

  Here, the noble gas is a group 18 element of the periodic table, specifically helium, neon, argon, krypton, xenon, radon, etc., and in the present invention, helium or argon is preferably used. I can do it. These may be used as a mixture, for example, in a ratio of helium 3: argon 7 or the like.

  The concentration of the rare gas or nitrogen in the reaction gas is preferably 90% or more in order to generate a stable plasma discharge, and desirably 90 to 99.99% by volume.

  A rare gas or nitrogen is used to generate a stable plasma discharge, and the reactive gas is ionized or radicalized in the plasma, and is deposited or adhered to the surface of the substrate to form a thin film.

  As the reactive gas useful in the present invention, a thin film having various functions can be formed on an optical film by using a reactive gas to which reactive gases of various substances are added.

  For example, the low refractive index layer or the antifouling layer of the antireflection layer can be formed using a fluorine-containing organic compound or a silicon compound as the reactive gas.

  Further, these metal oxide layers (metal oxide nitride layers) using organometallic compounds, metal hydrides, and metal halides containing Ti, Zr, In, Sn, Zn, Ge, Si or other metals. Or a metal nitride layer or the like. These layers may be a middle refractive index layer or a high refractive index layer of the antireflection layer, or may be a conductive layer or an antistatic layer.

  Further, an antifouling layer and a low refractive index layer can be formed with a fluorine-containing organic compound, and a gas barrier layer and a low refractive index layer can be formed with a silicon compound. The present invention is particularly preferably used for forming an antireflection layer formed by alternately laminating high, medium refractive index layers and low refractive index layers.

  The film thickness of the formed metal oxide layer is preferably in the range of 1 nm to 1000 nm.

  In the atmospheric pressure plasma treatment, a fluorine compound-containing layer can be formed by using a fluorine-containing organic compound as a source gas.

  As the fluorine-containing organic compound, a fluorocarbon gas, a fluorinated hydrocarbon gas, or the like is preferable.

Specifically, as the fluorine-containing organic compound, for example, a fluorocarbon compound such as carbon tetrafluoride, carbon hexafluoride, tetrafluoroethylene, hexafluoropropylene, and octafluorocyclobutane;
Fluorinated hydrocarbon compounds such as difluoromethane, tetrafluoroethane, propylene tetrafluoride, propylene trifluoride, and cyclobutane octafluoride;
Further, halides of fluorinated hydrocarbon compounds such as trichloromethane trichloride, dichloromethane monofluoride, cyclobutane dichloride, and fluorine-substituted products of organic compounds such as alcohols, acids, and ketones. I can do it.

  These may be used alone or in combination. Examples of the fluorinated hydrocarbon gas include gases such as difluoromethane, tetrafluoroethane, propylene tetrafluoride, and propylene trifluoride.

  Furthermore, it is possible to use halides of fluorinated hydrocarbon compounds such as methane monochloride trifluoride methane, monochloride difluoride methane, and dichloride tetrafluorocyclobutane, and fluorine substitution products of organic compounds such as alcohols, acids, and ketones. However, the present invention is not limited to these.

  Moreover, these compounds may have an ethylenically unsaturated group in the molecule. In addition, the above compounds may be used as a mixture.

  When a fluorine-containing organic compound is used as the reactive gas, the content of the fluorine-containing organic compound as the reactive gas in the reactive gas is from the viewpoint of forming a uniform thin film on the cellulose ester film by plasma discharge treatment. It is preferable that it is 01-10 volume%, More preferably, it is 0.1-5 volume%.

  Further, when the fluorine-containing organic compound preferably used is a gas at normal temperature and pressure, it can be used as it is as a component of the reactive gas.

  Further, when the fluorine-containing organic compound is liquid or solid at normal temperature and pressure, it may be vaporized by vaporization means, for example, by heating, decompression, etc., or may be dissolved in an appropriate organic solvent. .

  Examples of silicon compounds useful as reactive gases include organometallic compounds such as dimethylsilane and tetramethylsilane, metal hydrides such as monosilane and disilane, metal halogens such as silane dichloride, silane trichloride, and silicon tetrafluoride. It is preferable to use a compound, an alkoxysilane such as tetramethoxysilane, tetraethoxysilane, tetraisopropoxysilane, dimethyldiethoxysilane, methyltriethoxysilane, ethyltriethoxysilane, or the like, but is not limited thereto.

  Moreover, these can be used in combination as appropriate. Alternatively, another organic compound can be added to change or control the physical properties of the film.

  When a silicon compound is used as the reactive gas, the content of the silicon compound as the reactive gas in the reactive gas is 0.01 to 10 volumes from the viewpoint of forming a uniform thin film on the cellulose ester film by plasma discharge treatment. %, Preferably 0.1 to 5% by volume.

  Although it does not specifically limit as an organometallic compound useful as a reactive gas, Al, As, Au, B, Bi, Sb, Ca, Cd, Cr, Co, Cu, Fe, Ga, Ge, Hg, In, Li Preferable organic metal compounds for forming metal compounds such as Mg, Mn, Mo, Na, Ni, Pb, Pt, Rh, Se, Si, Sn, Ti, Zr, Y, V, W, and Zn I can do it.

  For example, in order to form a high refractive index layer of the antireflection layer, a titanium compound is preferable. Specifically, for example, an organic amino metal compound such as tetradimethylamino titanium, a metal hydrogen compound such as monotitanium and dititanium, Examples thereof include metal halogen compounds such as titanium chloride, titanium trichloride, and titanium tetrachloride, and metal alkoxides such as tetraethoxy titanium, tetraisopropoxy titanium, and tetrabutoxy titanium.

  The above silicon compounds and organometallic compounds are preferably metal hydrides and metal alkoxides from the viewpoint of handling, and are preferably used since metal alkoxides are not corrosive, do not generate harmful gases, and have little contamination in the process. It is done.

  When using an organometallic compound as the reactive gas, from the viewpoint of forming a uniform thin film on the cellulose ester film by plasma discharge treatment, the content of the organometallic compound as the reactive gas in the reactive gas is 0.01 to Although it is preferable that it is 10 volume%, More preferably, it is 0.1-5 volume%.

  Further, in order to introduce a metal compound such as a silicon compound or a titanium compound into the discharge part, both can be used in a gas, liquid or solid state at normal temperature and pressure.

  In the case of gas, it can be introduced into the discharge part as it is, but in the case of liquid or solid, it can be used after being vaporized by means of vaporization such as heating, decompression or ultrasonic irradiation.

  When metal compounds such as silicon compounds and titanium compounds are vaporized by heating, metal alkoxides that are liquid at room temperature and have a boiling point of 200 ° C. or less, such as tetraethoxysilane and tetraisopropoxytitanium, are used in the present invention. It is suitable for a method for forming a metal oxide thin film layer. The metal alkoxide may be used after diluted with an organic solvent. As the organic solvent, an organic solvent such as methanol, ethanol, n-hexane, or a mixed organic solvent thereof can be used.

  Furthermore, physical properties such as hardness and density of the thin film layer can be obtained by adding 0.1 to 10% by volume of oxygen, hydrogen, carbon dioxide, carbon monoxide, nitrogen, nitrogen dioxide, nitrogen monoxide, water, etc. in the reaction gas. Can be controlled.

  By the above method, an amorphous metal oxide layer such as silicon oxide or titanium oxide can be preferably produced.

  The cellulose ester film provided with the cured resin layer of the present invention is preferably used for, for example, an optical film having an antireflection layer obtained by laminating a low refractive index layer and a high refractive index layer, a conductive layer, an optical film having an antistatic layer, or the like. I can do it. In particular, it is preferable because these layers have excellent adhesion.

  In the present invention, by providing a plurality of plasma discharge devices, a multilayer thin film can be continuously provided, and a multilayer laminate can be formed without unevenness of the thin film.

  For example, when producing an antireflection film having an antireflection layer on a cellulose ester film provided with the cured resin layer of the present invention, a high refractive index layer having a refractive index of 1.6 to 2.3 and a refractive index of 1.3 to A low refractive index layer of 1.5 can be continuously laminated on the surface of the cellulose ester film to produce efficiently.

  As the low refractive index layer, a fluorine-containing compound layer formed by plasma discharge treatment using a gas containing a fluorine-containing organic compound, or silicon oxide mainly formed by plasma discharge treatment using an organosilicon compound such as alkoxysilane is used. The high refractive index layer is preferably a metal oxide layer formed by plasma discharge treatment with a gas containing an organometallic compound, such as a layer having titanium oxide or zirconium oxide.

  Although there are thinning methods described above, the present invention is not limited to these methods, and the layer structure is not limited thereto. For example, an antifouling layer may be provided on the outermost surface by plasma discharge treatment in the presence of a fluorine-containing organic compound gas in the presence of atmospheric pressure or in the vicinity thereof.

  According to the above method, in the present invention, multilayer thin films can be laminated, and a uniform antireflection film can be obtained without unevenness in the thickness of each layer.

<Polarizer>
The polarizing plate of the present invention will be described.

  The polarizing plate can be produced by a general method. The cellulose ester film provided with the cured resin layer of the present invention or the hard coat film obtained by subjecting the back side of the antireflection film to alkali saponification treatment by dipping and stretching in an iodine solution is completely saponified. It is preferable to bond together using an aqueous polyvinyl alcohol solution. The film may be used on the other surface, or another polarizing plate protective film may be used. Commercially available cellulose ester films (for example, Konica Minoltak KC8UX, KC4UX, KC5UX, KC8UCR3, KC8UCR4, KC8UY, KC4UY, KC12UR, manufactured by Konica Minolta Opto Co., Ltd.) are preferably used. The polarizing plate protective film used on the other surface of the optical film of the present invention preferably has an in-plane retardation Ro of 590 nm, a phase difference of 20 to 70 nm, and Rt of 100 to 400 nm. . These can be produced, for example, by the method described in JP-A-2002-71957 and Japanese Patent Application No. 2002-155395. Alternatively, it is preferable to use a polarizing plate protective film that also serves as an optical compensation film having an optically anisotropic layer formed by aligning a liquid crystal compound such as a discotic liquid crystal. For example, the optically anisotropic layer can be formed by the method described in JP-A-2003-98348. By using in combination with the hard coat film of the present invention, a polarizing plate having excellent flatness and a stable viewing angle expansion effect can be obtained.

  The polarizing film, which is the main component of the polarizing plate, is an element that transmits only light having a polarization plane in a certain direction. A typical polarizing film known at present is a polyvinyl alcohol polarizing film, which is a polyvinyl alcohol film. There are one in which iodine is dyed on a system film and one in which dichroic dye is dyed. As the polarizing film, a polyvinyl alcohol aqueous solution is formed and dyed by uniaxially stretching or dyed, or uniaxially stretched after dyeing, and then preferably subjected to a durability treatment with a boron compound. On the surface of the polarizing film, one side of the optical film of the present invention is bonded to form a polarizing plate. It is preferably bonded with an aqueous adhesive mainly composed of completely saponified polyvinyl alcohol or the like.

  A polarizing plate using a conventional hard coat film is inferior in flatness, and when the reflected image is seen, fine wavy unevenness is recognized. According to a durability test under the conditions of 60 ° C. and 90% RH, the wavy unevenness is observed. In contrast, the polarizing plate using the hard coat film of the present invention was excellent in flatness. Further, even in the durability test under the conditions of 60 ° C. and 90% RH, the wavy unevenness did not increase.

<Display device>
By incorporating the polarizing plate of the present invention into a display device, the display device of the present invention having various visibility can be manufactured. The optical film of the present invention is preferably a reflective, transmissive, transflective LCD, or TN, STN, OCB, HAN, VA (PVA, MVA), IPS, or other driving LCD. Used. In addition, the antireflection film in which the antireflection layer is formed on the optical film of the present invention has remarkably little color unevenness of the reflected light of the antireflection layer, and is excellent in flatness, plasma display, field emission display, organic EL display, inorganic It is also preferably used for various display devices such as EL displays and electronic paper. Especially in a large-screen display device with a 30-inch screen or more, a reflection image of a fluorescent lamp that appears to be distorted due to uneven color or undulation is not distorted like the reflection of a mirror. But there was an effect that eyes were not tired.

  EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to these.

  First, a method for evaluating a sample manufactured according to the present invention will be described.

<< Flatness index; Evaluation of minute irregularities >>
Laser displacement meter: Keyence Co., Ltd., Model: LT-8100, Resolution: 0.2 μm, Scan with a laser displacement meter in the width direction to measure fine undulations on the surface, and the flatness of the optical film evaluated.

  The measuring method is that the film is placed on a flat and horizontal table, both ends of the width are fixed to the table with tape, and the measuring camera is set in parallel with the table on a moving rail made by Sigma Kogyo Co., Ltd. And the sample film were set so that the distance between them was 25 mm, and the measurement was performed by scanning at a moving speed of 5 cm / min. The value obtained by the measurement is the state and size of minute irregularities on the film surface.

A: Unevenness due to film deformation is less than 0.5 μm ○: Unevenness due to film deformation is less than 0.5 to 1.0 μm Δ: Unevenness due to film deformation is less than 1.0 to 3.0 μm ×: Due to film deformation Unevenness is 3.0 μm or more <<Flatness; Visual evaluation >>
Cut each sample into a size of 90cm in width and 100cm in length, and arrange five 50W fluorescent lamps at a height of 1.5m so that the sample stage can be illuminated from a 45 ° angle. Each film sample was placed, and the unevenness that was reflected on the surface of the optical film was visually observed and judged as follows. By this method, it is possible to determine “tsun” and “wrinkle”.

◎: All five fluorescent lamps look straight ○: Some fluorescent lamps appear to be bent slightly △: Fluorescent lamps appear to be slightly bent as a whole ×: Fluorescent lamps appear to swell largely << Adhesion >>
A cross-cut test based on JIS K 5400 was performed. Specifically, 11 cuts were made vertically and horizontally at intervals of 1 mm on the coated surface of the cured resin layer to make 100 1 mm square grids. The cellophane tape was affixed on this, peeled off quickly at an angle of 90 degrees, and the number of grids remaining without peeling was expressed as m / 100.

A: 0 ≦ m <15 Excellent adhesion ○: 0 ≦ m <30 Excellent adhesion Δ: 31 ≦ m <50 A level that does not cause any practical problem x: 51 ≦ m <100 Peeling is noticeable and has practical problems << Evaluation of long-term storage >>
The optical film wound up in a roll shape was covered with a polyethylene sheet to prevent adhesion of dust, and was stored for a long time in a warehouse where the temperature and humidity were high. After storage for 1 month at 40 ° C. and 80% RH, the flatness of the film was visually evaluated using the evaluation method of “flatness; visual evaluation”.

<Visibility evaluation>
The liquid crystal panel (liquid crystal display device) was visually observed, and the visibility in the oblique direction was evaluated as follows.

◎: Black appears to be clear and clear, and no white spots appear in the image. ○: Black appears to be clear and clear, but slight white spots appear in the image. △: Slightly black spots appear. The sharpness is slightly low and white spots of the image are observed. X: No black spots are observed, the sharpness is low and the white spots of the image are worrisome. In the present invention, ○ and ◎ are practical.

Example 1
(Production of cellulose ester film)
A film of 80 μm is produced by melt film formation using cellulose acetate (CAP-504-0.2 manufactured by Eastman Chemical Co., Ltd.) under the processing conditions, plasticizer, ultraviolet absorber and fine particles added as shown in Table 1 below. Thus, a cellulose ester film 1 having a width of 1.5 m was obtained. A knurling having a width of 10 μm and a width of 15 mm was provided at both ends of the width.

  The film contains 0.6% by mass of epoxidized tall oil, 0.4% by mass of para-tert-butylphenol, 0.07% by mass of neopentylphenyl phosphite, 0.02% by mass of strontium naphthoate as a heat stabilizer. % Was added.

  Similarly, cellulose ester films 2 to 4 were obtained in the same manner except that the types of cellulose ester and plasticizer were changed as shown in Table 1.

  Cellulose acetate (CAP-482-0.5) was dissolved using a solvent having a methylene chloride: methanol mass ratio of 95: 5, and a film having a thickness of 80 μm was produced by employing a solution casting film forming method using the solvent. Cellulose ester film 5 (comparative example) was obtained. The cellulose ester film 5 used triphenyl phosphate as a plasticizer.

<Cellulose ester>
Cellulose acetate propionate (CAP-504-0.2, CAP-482-0.5 (Eastman Chemical Co.))
<Plasticizer>
A: Trimethylolpropane tribenzoate (polyhydric alcohol ester)
B: Tripropylene glycol dibenzoate (polyhydric alcohol ester)
C: Trinaphthyl phosphate D: Tris ortho-biphenyl phosphate E: Triphenyl phosphate <Ultraviolet absorber>
A: Polymer ultraviolet absorber PUV-17 described in JP-A No. 2003-113317
B: Polymer ultraviolet absorber PUV-19 described in JP-A No. 2003-113317
<Fine particles>
A: Aerosil R972V (manufactured by Nippon Aerosil Co., Ltd.)
(Preparation of hard coat film)
<Coating of cured resin layer>
Cellulose ester film No. Each of 1 to 5 was subjected to hydrophilic treatment on the surface by alkali saponification treatment. That is, after immersing in 1 mol / L sodium hydroxide at 50 ° C. for 1 minute, neutralized, washed with water and subjected to alkali saponification treatment, the following coating solution for cured resin layer (ultraviolet curable resin layer) was applied to a micro gravure coater. After coating at 90 ° C. and drying at 90 ° C., the coating layer is cured using an ultraviolet lamp at an irradiation part with an illuminance of 100 mW / cm ² and an irradiation dose of 0.1 J / cm ² , and a cured resin having a thickness of 6 μm. The layer was formed and the hard coat film 1 of this invention was obtained.

<Coating liquid for cured resin layer>
Polymerizable compound Exemplified compound A3-1 35 parts by weight Photopolymerization initiator The following compound 2 parts by weight Water 40 parts by weight Trietheramine was appropriately added to adjust the pH to 8.5. The coating solution was filtered through a polypropylene filter having a pore size of 0.4 μm to prepare a cured resin layer coating solution.

  Furthermore, hard coat films 2 to 16 were produced in the same manner except that the solvent composition of the coating solution and the cellulose ester film were changed as shown in Table 2.

  About the obtained hard coat film, flatness index | exponent, flatness: Visual observation, adhesiveness, and long-term storage property were evaluated on the above-mentioned conditions. The results are shown in Table 3.

  From the above table, the films 1-4 of the present invention, 6-9, and 11-15 are compared with the films 5, 10 and 16 of the comparative examples by increasing the water content in the hard coat coating composition. Thus, it was found that the above characteristics were improved.

Example 2
Before applying the cured resin layer using the cellulose ester films 1 and 2 prepared in Example 1, the cellulose ester film was subjected to corona discharge treatment or ultraviolet irradiation treatment under the following conditions to coat the cured resin layer. As the coating composition for the cured resin layer, a coating composition in which the solvent composition was changed as shown in Table 4 was used.

Corona discharge treatment: The cellulose ester film was treated using a corona discharge treatment apparatus described in JP-A-10-296856 under the condition of 8 W / m ² · min.

Ultraviolet irradiation treatment: The cellulose ester film was irradiated with a low-pressure mercury lamp for 30 seconds and treated with a light amount of 300 mJ / cm ² .

  Adhesiveness was evaluated with respect to the obtained hard coat films 17-22. The results are shown in Table 4.

  From the above table, it is clear that the adhesion between the hard coat film and the substrate is further improved by performing the surface activation treatment.

Example 3
(Preparation of antireflection film)
An antireflection layer was formed on the hard coat film prepared above.

  Hard coat film No. The coating liquid for the refractive index layer shown below is applied onto 1-22, using a wire bar coater, dried at 70 ° C., and then irradiated with ultraviolet rays to cure the coating layer. The rate was 1.72 and the film thickness was 80 nm. On top of that, the following coating solution for a high refractive index layer was applied using a wire bar coater, dried at 70 ° C., then irradiated with ultraviolet rays to cure the coating layer, and a high refractive index layer (refractive index 1.9). , A film thickness of 70 nm) was formed. Furthermore, the following coating liquid 1 or 2 for a low refractive index layer is applied using a wire bar coater, dried at 70 ° C., cured by heat treatment to form a low refractive index layer (film thickness 95 nm), An antireflection film No. having a visible light reflectance of 0.5% or less. 1-22 were produced.

<Preparation of medium refractive index layer / high refractive index layer / low refractive index layer>
(Preparation of titanium dioxide dispersion)
Titanium dioxide (primary particle mass average particle diameter: 50 nm, refractive index: 2.70) 30 parts by mass, anionic diacrylate monomer (PM21, Nippon Kayaku Co., Ltd.) 4.5 parts by mass, cationic methacrylate monomer (DMAEA, manufactured by Kojin Co., Ltd.) 0.3 parts by mass and 65.2 parts by mass of methyl ethyl ketone were dispersed by a sand grinder to prepare a titanium dioxide dispersion.

(Preparation of coating solution for medium refractive index layer)
In 151.9 g of cyclohexanone and 37.0 g of methyl ethyl ketone, 0.14 g of a photopolymerization initiator (Irgacure 907, manufactured by Ciba Geigy) and 0.04 g of a photosensitizer (Kayacure DETX, manufactured by Nippon Kayaku Co., Ltd.) were dissolved. Further, 6.1 g of the above titanium dioxide dispersion and 2.4 g of a mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate (DPHA, manufactured by Nippon Kayaku Co., Ltd.) were added and stirred at room temperature for 30 minutes. The solution was filtered through a polypropylene filter having a pore diameter of 0.4 μm to prepare a coating solution for a medium refractive index layer. When this coating solution was applied to a cellulose ester film and dried and the refractive index after UV curing was measured, a medium refractive index layer having a refractive index of 1.72 was obtained.

(Preparation of coating solution for high refractive index layer)
In 1152.8 g of cyclohexanone and 37.2 g of methyl ethyl ketone, 0.06 g of a photopolymerization initiator (Irgacure 907, manufactured by Ciba Geigy) and 0.02 g of a photosensitizer (Kayacure DETX, manufactured by Nippon Kayaku Co., Ltd.) were dissolved. Furthermore, the ratio of the above titanium dioxide dispersion and the titanium dioxide dispersion of a mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate (DPHA, Nippon Kayaku Co., Ltd.) is increased, and the refractive index of the high refractive index layer is increased. The amount was adjusted so as to be a ratio, and the mixture was stirred at room temperature for 30 minutes, and then filtered through a polypropylene filter having a pore size of 0.4 μm to prepare a coating solution for a high refractive index layer. When this coating solution was applied to a cellulose ester film, dried and the refractive index after UV curing was measured, a high refractive index layer having a refractive index of 1.9 was obtained.

(Preparation of coating solution for low refractive index layer)
Hard coat film No. The following coating solution 1 for a low refractive index layer was coated on 1 to 16 high refractive index layers.

(Preparation of coating solution 1 for low refractive index layer)
Silane coupling agent (KBM-503, Shin-Etsu Silicone Co., Ltd.) 3 g and 0.1 M / L hydrochloric acid 2 g were added to 200 g of methanol dispersion of silica fine particles with an average particle size of 15 nm (methanol silica sol, manufactured by Nissan Chemical Co., Ltd.). In addition, the mixture was stirred at room temperature for 5 hours and then allowed to stand at room temperature for 3 days to prepare a dispersion of silica fine particles treated with silane coupling. To 35.04 g of the dispersion, 58.35 g of isopropyl alcohol and 39.34 g of diacetone alcohol were added. Further, 1.02 g of a photopolymerization initiator (Irgacure 907, manufactured by Ciba Geigy) and a solution obtained by dissolving 0.51 g of a photosensitizer (Kayacure DETX, manufactured by Nippon Kayaku Co., Ltd.) in 772.85 g of isopropyl alcohol were added. Furthermore, 25.6 g of a mixture of dipentaerythritol pentaacrylate and dipentaerythritol hexaacrylate (DPHA, manufactured by Nippon Kayaku Co., Ltd.) was added and dissolved. 67.23 g of the resulting solution was added to the above dispersion, a mixture of isopropyl alcohol and diacetone alcohol. The mixture was stirred for 20 minutes at room temperature and filtered through a polypropylene filter having a pore size of 0.4 μm to prepare a coating solution for a low refractive index layer. When this coating solution was applied to a cellulose ester film and dried, and the refractive index after UV curing was measured, the refractive index was 1.45.

  Next, hard coat film No. The following coating solution 2 for a low refractive index layer was coated on the 17 to 22 high refractive index layer.

(Preparation of coating solution 2 for low refractive index layer)
First, silica-based fine particles (cavity particles) were prepared.

(Preparation of silica-based fine particles P-1)
A mixture of 100 g of silica sol having an average particle diameter of 5 nm and a SiO ₂ concentration of 20% by mass and 1900 g of pure water was heated to 80 ° C. The pH of this reaction mother liquor was 10.5, and 9000 g of 0.98 mass% sodium silicate aqueous solution as SiO ₂ and 9000 g of 1.02 mass% sodium aluminate aqueous solution as Al ₂ O ₃ were simultaneously added to the mother liquor. did. Meanwhile, the temperature of the reaction solution was kept at 80 ° C. The pH of the reaction solution rose to 12.5 immediately after the addition, and hardly changed thereafter. After completion of the addition, the reaction solution was cooled to room temperature and washed with an ultrafiltration membrane to prepare a SiO ₂ .Al ₂ O ₃ core particle dispersion having a solid content concentration of 20% by mass. (Process (a))
1700 g of pure water is added to 500 g of this core particle dispersion and heated to 98 ° C., and while maintaining this temperature, a silicic acid solution (SiO ₂₎ obtained by dealkalizing a sodium silicate aqueous solution with a cation exchange resin. A dispersion of core particles in which 3000 g (concentration of 3.5% by mass) was added to form a first silica coating layer was obtained. (Process (b))
Next, 1125 g of pure water is added to 500 g of the core particle dispersion liquid that has been washed with an ultrafiltration membrane to form a first silica coating layer having a solid content concentration of 13% by mass, and concentrated hydrochloric acid (35.5%) is further added dropwise. The pH was adjusted to 1.0 and dealumination was performed. Next, the aluminum salt dissolved in the ultrafiltration membrane was separated while adding 10 L of hydrochloric acid aqueous solution of pH 3 and 5 L of pure water, and SiO ₂ · Al from which some of the constituent components of the core particles forming the first silica coating layer were removed. A dispersion of ₂ O ₃ porous particles was prepared (step (c)). A mixture of 1500 g of the above porous particle dispersion, 500 g of pure water, 1,750 g of ethanol, and 626 g of 28% ammonia water is heated to 35 ° C., and then 104 g of ethyl silicate (SiO ₂ 28 mass%) is added. The surface of the porous particles on which the first silica coating layer was formed was coated with a hydrolyzed polycondensate of ethyl silicate to form a second silica coating layer. Next, a dispersion of silica-based fine particles having a solid content concentration of 20% by mass was prepared by replacing the solvent with ethanol using an ultrafiltration membrane.

Table 5 shows the thickness, average particle diameter, MOx / SiO ₂ (molar ratio), and refractive index of the first silica coating layer of the silica-based fine particles. Here, the average particle diameter was measured by a dynamic light scattering method, and the refractive index was measured in the same manner as described above.

Next, 95 mol% of Si (OC ₂ H ₅ ) ₄ , C ₃ F ₇ — (OC ₃ F ₆ ) ₂₄ —O— (CF ₂ ) ₂ —C ₂ H ₄ —O—CH ₂ Si (OCH ₃ ) ₃ 30% by mass of the silica-based fine particles P-1 having an average particle diameter of 60 nm are added to a matrix mixed with 5 mol%, 1.0N-HCl is used as a catalyst, and the refractive index coating is further diluted with a solvent. A coating agent is prepared on the high refractive index layer using a die coater method in a film thickness of 0.1 μm, dried at 120 ° C. for 1 minute, and then irradiated with ultraviolet rays to obtain a refractive index of 1.37. The low refractive index layer was formed.

  A polarizing plate was produced using each of the produced antireflection films.

(Preparation of polarizing plate)
A polyvinyl alcohol film having a thickness of 120 μm was uniaxially stretched (temperature: 110 ° C., stretch ratio: 5 times). This was immersed in an aqueous solution composed of 0.075 g of iodine, 5 g of potassium iodide and 100 g of water for 60 seconds, and then immersed in an aqueous solution of 68 ° C. composed of 6 g of potassium iodide, 7.5 g of boric acid and 100 g of water. This was washed with water and dried to obtain a polarizing film.

  Subsequently, according to the following processes 1-5, the polarizing film, the said antireflection film, and the cellulose ester film of the back side were bonded together, and the polarizing plate was produced. As the polarizing plate protective film on the back surface side, a cellulose ester film having a retardation (measured at 590 nm, in-plane retardation Ro = 43 nm, retardation in the thickness direction Rt = 135 nm) was used as a polarizing plate.

  Step 1: Soaked in a 2 mol / L sodium hydroxide solution at 60 ° C. for 90 seconds, then washed with water and dried to obtain a saponified cellulose ester film bonded to the polarizer.

  On the other hand, the surface of the anti-reflection layer side of the hard coat film on which the anti-reflection layer was formed was subjected to the saponification treatment while applying a peelable polyethylene film and protecting it from alkali.

  Step 2: The polarizing film was immersed in a polyvinyl alcohol adhesive tank having a solid content of 2% by mass for 1 to 2 seconds.

  Step 3: Gently wipe off the excess adhesive adhering to the polarizing film in Step 2 and place it on the cellulose ester film treated in Step 1, so that the antireflection layer of the hard coat film is on the outside Laminated and placed.

Step 4: Excess adhesive and bubbles were removed from the end of the laminate of the antireflection film, the polarizing film and the cellulose ester film sample laminated in Step 3 with a hand roller, and bonded together. The pressure of the hand roller was 20 to 30 N / cm ² and the roller speed was about 2 m / min.

  Process 5: The sample which bonded the polarizing film produced in the process 4, the cellulose-ester film, and the antireflection film in the 80 degreeC dryer was dried for 2 minutes, and the polarizing plate was produced. Antireflection film No. 1 to 22, and polarizing plate No. 1-22 were produced.

(Production of liquid crystal display device)
A liquid crystal panel for viewing angle measurement was produced as follows, and the characteristics as a liquid crystal display device were evaluated.

  The polarizing plates on both sides of the 15-inch display VL-150SD manufactured by Fujitsu were previously peeled off, and the produced polarizing plates 1 to 22 were each stuck to the glass surface of the liquid crystal cell.

  At that time, the direction of bonding of the polarizing plate is such that the surface of the optical compensation film (retardation film) is on the liquid crystal cell side and the absorption axis is in the same direction as the polarizing plate previously bonded. The liquid crystal display device no. 1-22 were produced respectively.

  Each liquid crystal display device thus obtained was allowed to stand for 100 hours under conditions of 60 ° C. and 90% RH, then returned to 23 ° C. and 55% RH, and the visibility was evaluated.

  The results are shown in Tables 3 and 4 above. As a result, it was found that the liquid crystal display device using the hard coat film according to the present invention was excellent in visibility.

  Separately, the viewing angle was measured in each liquid crystal display device by EZ-contrast manufactured by ELDIM. The viewing angle was expressed in the range of the tilt angle from the normal direction with respect to the panel surface where the contrast ratio between the white display and the black display of the liquid crystal cell is 10 or more. As a result, the liquid crystal display device No. 1 of the present invention using the polarizing plate of the present invention was used. 1 to 16 are 160 ° or more when measured from an oblique 45 ° direction. It was confirmed that 17 to 22 had a viewing angle of 170 ° or more. Moreover, even if there was a reflection of a fluorescent lamp from an oblique direction, the black color appeared to appear, there was no uneven color of the reflected light, and the eyes did not get tired. On the other hand, in the comparative liquid crystal display devices 5, 10, and 16, black from an oblique direction cannot be seen due to fine wavy unevenness, the visibility is inferior, and the visibility improvement effect by widening the viewing angle is reduced. I was sorry.

It is a figure which shows an example of the plasma discharge processing apparatus used in forming the metal oxide layer of this invention. It is a figure which shows an example of the plasma discharge processing apparatus which has a rotating electrode useful for forming the metal oxide thin film layer of this invention, and a fixed electrode.

Explanation of symbols

F optical film G reactive gas G ′ exhaust gas 10A, 10B, 110 rotating electrode 11A, 11B, 11C, 11D U turn roll 20, 21 guide roll 30 reactive gas supply unit 40, 140 gas exhaust port 50, 150 discharge unit 51 rectifying plate 51 80, 180 Power supply 81, 82, 181, 182 Voltage supply means 111 Fixed electrode 120, 121 Guide roll 122, 123 Nip roll 124, 125 Partition plate 130 Air supply pipe 131 Reactive gas generator 190 Plasma discharge treatment vessel

Claims (18)

The coating composition for a cured resin layer containing at least a resin and a solvent contains 10% by mass to 70% by mass of a solid content, 30% by mass or more of moisture in all solvents, and the coating composition for a cured resin layer An optical film characterized in that a cured resin layer is provided on a cellulose ester film substrate formed by melt casting. The optical film according to claim 1, wherein the cellulose ester film substrate contains two or more kinds of plasticizers. The optical film according to claim 1, wherein the cured resin layer coating composition is coated on the cellulose ester film substrate and then cured by actinic radiation. The optical film according to any one of claims 1 to 3, wherein the cellulose ester film substrate is subjected to a surface modification treatment before the coating composition for a cured resin layer is applied. The optical film according to claim 4, wherein the surface modification treatment is corona discharge treatment, ultraviolet irradiation treatment, plasma discharge treatment, or alkali saponification treatment. The optical film according to claim 1, wherein the solvent is a water-miscible organic solvent. The optical film according to any one of claims 1 to 6, wherein a width of the cellulose ester film substrate is in a range of 1.4 m to 4 m. The cellulose ester film substrate contains at least one selected from cellulose acetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, cellulose acetate butyrate, cellulose acetate phthalate, and cellulose phthalate. The optical film according to any one of claims 1 to 7. The cellulose ester film substrate is a film stretched by 1.00 to 2.50 times and 1.01 to 3.00 times in one direction and a direction orthogonal thereto, respectively. 9. The optical film according to any one of 8 above. The coating composition for a cured resin layer containing at least a resin and a solvent contains 10% by mass to 70% by mass of a solid content, 30% by mass or more of moisture in all solvents, and the coating composition for a cured resin layer It is a manufacturing method of the optical film which apply | coats on the cellulose-ester film base material formed by melt casting, and provides a cured resin layer, Comprising: This cellulose-ester film is 1.00-2. A method for producing an optical film, wherein the coating composition is applied on a cellulose ester film substrate stretched 50 times, 1.01 to 3.00 times, and further cured by actinic radiation. The method for producing an optical film according to claim 10, wherein the cellulose ester film substrate is subjected to a surface modification treatment before the coating composition for a cured resin layer is applied. The method for producing an optical film according to claim 11, wherein the surface modification treatment is corona discharge treatment, ultraviolet irradiation treatment, plasma discharge treatment, or alkali saponification treatment. An antireflection film, comprising an antireflection layer provided on at least one surface of the optical film according to claim 1. The antireflection layer has a low refractive index layer, the low refractive index layer contains inorganic fine particles, and the inorganic fine particles are porous particles or a composite particle having a coating layer provided on the surface of the porous particles; The antireflection film according to claim 13, wherein the antireflection film is a hollow particle filled with a solvent, a gas, or a porous material. A polarizing plate using the optical film according to claim 1 on at least one surface. A polarizing plate, wherein the antireflection film according to claim 13 or 14 is used on at least one surface. A liquid crystal display device using the optical film according to claim 1. A liquid crystal display device using the polarizing plate according to claim 15 or 16.

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