Anti-glare layered body, optical layered body, polarizing plate, and image display device

Abstract

The present invention provides a glare-resistant laminate having excellent pencil hardness and bending resistance. A glare-resistant laminate, which is a glare-resistant laminate having a resin layer on a substrate, wherein the resin layer has a first resin layer and a second resin layer from the substrate side, the resin layer contains first particles having an average particle diameter of 0.5 μm or more, and 70% or more of the first particles exist across the first resin layer and the second resin layer on a number basis, the glare-resistant laminate satisfying the following formula 1. 5 < t1 / t2 < 15 (Formula 1) [In formula 1, t1 represents the average thickness of the first resin layer, and t2 represents the average thickness of the second resin layer].

Description

Technical Field

[0001] This invention relates to anti-glare laminates, optical laminates, polarizers, and image display devices. Background Technology

[0002] To achieve anti-glare properties, anti-glare laminates are sometimes applied to the surface of image display devices such as televisions, laptops, and desktop computer monitors. Anti-glare refers to the property of suppressing the reflection of lighting and background elements such as people.

[0003] In addition, optical laminates are sometimes provided on the surface of image display devices to provide properties such as anti-fouling, anti-reflective, and anti-glare.

[0004] Anti-glare laminates consist of a basic structure consisting of an anti-glare layer with an uneven surface on a substrate. Anti-glare laminates are mostly used as surface components in image display devices, etc., and therefore have frequent contact with fingers and objects. Therefore, anti-glare laminates with high pencil hardness are preferred.

[0005] Optical laminates consist of a basic structure with optically functional layers on a substrate. Optical laminates are mostly used as surface components in image display devices, and therefore have frequent contact with human fingers and objects. Therefore, optical laminates with good pencil hardness are preferred.

[0006] In order to improve the pencil hardness of the anti-glare laminate, the resin component of the anti-glare layer is preferably a cured product of a curable resin composition (for example, Patent Documents 1-2).

[0007] To improve the pencil hardness of optical laminates, the binder resin used as the optical functional layer is preferably a cured product of a curable resin composition.

[0008] Cured resin compositions readily improve the pencil hardness of optical laminates, but tend to have poor adhesion to the substrate. Patent documents 3 and 4 propose optical laminates that use cured resin compositions as adhesive resins for optical functional layers and exhibit good adhesion.

[0009] Existing technical documents

[0010] Patent documents

[0011] Patent Document 1: Japanese Patent No. 6840215

[0012] Patent Document 2: International Publication No. WO2018 / 070426

[0013] Patent Document 3: Japanese Patent Application Publication No. 2012-234163

[0014] Patent Document 4: Japanese Patent Application Publication No. 2015-188772 Summary of the Invention

[0015] The problem that the invention aims to solve

[0016] The anti-glare laminates of Patent Documents 1 and 2 exhibit good pencil hardness due to the high hardness of the anti-glare layer. However, the anti-glare laminates of Patent Documents 1 and 2 sometimes have insufficient flexural resistance. Specifically, when the anti-glare laminates of Patent Documents 1 and 2 are applied to foldable or rollable image display devices, cracks may occur in the anti-glare laminate. Furthermore, the aforementioned flexural resistance tends to deteriorate when using an acrylic resin substrate as the substrate for the anti-glare laminate.

[0017] The optical laminates of Patent Documents 3 and 4 exhibit good initial adhesion. However, the adhesion of the optical laminates of Patent Documents 3 and 4 decreases over time, or their optical properties change. Specifically, when the optical laminates of Patent Documents 3 and 4 are subjected to a lightfastness test using ultraviolet irradiation, the adhesion sometimes decreases, or the clarity of the transmitted image changes.

[0018] The objective of this invention is to provide an anti-glare laminate with excellent pencil hardness and bending resistance, as well as a polarizer and image display device using the anti-glare laminate.

[0019] The objective of this invention is to provide an optical laminate capable of suppressing the decrease in adhesion and the change in the clarity of transmitted images after a lightfastness test, as well as a polarizer and an image display device using the optical laminate.

[0020] Methods for solving problems

[0021] The present invention provides the following [1] to

[31] anti-glare laminates, optical laminates, polarizers and image display devices.

[0022] [1] An anti-glare laminate, which is an anti-glare laminate having a resin layer on a substrate, wherein,

[0023] The resin layer described above has a first resin layer and a second resin layer from the substrate side.

[0024] The aforementioned resin layer contains a first particle with an average particle size of 0.5 μm or more.

[0025] More than 70% of the aforementioned first particles exist across the aforementioned first resin layer and the aforementioned second resin layer.

[0026] The anti-glare laminate satisfies the following equation 1.

[0027] 5.0 < t1 / t2 < 15.0 (Equation 1)

[0028] [In Formula 1, t1 represents the average thickness of the above-mentioned first resin layer, and t2 represents the average thickness of the above-mentioned second resin layer.]

[0029] [2] The antiglare laminate according to [1], wherein D1 representing the average particle diameter of the above-mentioned first particles and t2 representing the average thickness of the above-mentioned second resin layer satisfy the relationship of t2 < D1.

[0030] [3] The antiglare laminate according to [1] or [2], wherein D1 representing the average particle diameter of the above-mentioned first particles and t1 representing the average thickness of the above-mentioned first resin layer satisfy the relationship of D1 < t1.

[0031] [4] The antiglare laminate according to any one of [1] to [3], wherein the above-mentioned first particles are organic particles.

[0032] [5] The antiglare laminate according to any one of [1] to [4], wherein the average inclination angle of the surface of the above-mentioned substrate on the resin layer side is 5.0 degrees or more and 15.0 degrees or less.

[0033] [6] The antiglare laminate according to any one of [1] to [5], wherein the arithmetic mean height of the surface of the above-mentioned substrate on the resin layer side is 0.05 μm or more and 0.25 μm or less.

[0034] [7] The antiglare laminate according to any one of [1] to [6], wherein H1 representing the indentation hardness at the exact middle in the thickness direction of the above-mentioned first resin layer and H2 representing the indentation hardness at the exact middle in the thickness direction of the above-mentioned second resin layer satisfy the relationship of H1 < H2.

[0035] [8] The antiglare laminate according to [7], which satisfies 40 MPa < H2 - H1.

[0036] [9] The antiglare laminate according to [7], which satisfies 40 MPa < H2 - H1 ≤ 100 MPa. <统一格式,将所有的替换为换行符,以符合中文习惯。

[0037]

[10] The antiglare laminate according to any one of [1] to [9], wherein the above-mentioned resin layer contains a cured product of a curable resin composition.

[0038]

[11] The antiglare laminate according to any one of [1] to

[10] , wherein the above-mentioned substrate is an acrylic resin substrate.

[0039]

[12] An antiglare laminate, which is an antiglare laminate having a resin layer on a substrate, wherein,

[0040] The above-mentioned resin layer contains first particles having an average particle diameter of 0.5 μm or more,

[0041] When the substrate side of the resin layer, extending from its center in the thickness direction, is defined as the first region, and the opposite side of the resin layer, extending from its center in the thickness direction, is defined as the second region, at least 70% of the first particles are present in the second region.

[0042] The anti-glare laminate satisfies either condition 1A or condition 2A.

[0043] <Condition 1A>

[0044] The average tilt angle of the surface of the resin layer side of the above-mentioned substrate is 5.0 degrees or more and 20.0 degrees or less.

[0045] <Condition 2A>

[0046] The arithmetic mean height of the surface of the resin layer side of the above-mentioned substrate is more than 0.10 μm and less than 0.40 μm.

[0047]

[13] The anti-glare laminate as described in

[12] , wherein D1, which represents the average particle size of the first particle, and t, which represents the average thickness of the resin layer, satisfy the relationship 2.0 < t / D1 < 6.0.

[0048]

[14] The anti-glare laminate as described in

[12] or

[13] , wherein the first particle is an organic particle.

[0049]

[15] The anti-glare laminate as described in any one of

[12] to

[14] , wherein the resin layer comprises a cured product of a curable resin composition.

[0050]

[16] The anti-glare laminate as described in any one of

[12] to

[15] , wherein the substrate is an acrylic resin substrate.

[0051]

[17] An optical laminate having a resin layer on a substrate, wherein,

[0052] The resin layer described above has a first resin layer and a second resin layer from the substrate side.

[0053] The first resin layer described above has mutually independent regions α1 and regions α2 surrounding regions α1. The resin contained in regions α1 is different from the resin contained in regions α2.

[0054] The second resin layer described above has a mutually independent region β1 and a region β2 surrounding the region β1. The resin contained in the region β1 is different from the resin contained in the region β2.

[0055] The optical laminate satisfies either condition 1B or condition 2B.

[0056] <Condition 1B>

[0057] The average tilt angle θa1 of the surface representing the resin layer side of the substrate and the average tilt angle θa2 of the surface representing the second resin layer side of the first resin layer satisfy the relationship θa2<θa1.

[0058] <Condition 2B>

[0059] Pa1, which represents the arithmetic mean height of the surface of the resin layer side of the substrate, and Pa2, which represents the arithmetic mean height of the surface of the second resin layer side of the first resin layer, satisfy the relationship Pa2 < Pa1.

[0060]

[18] The optical laminate as described in

[17] , wherein the above-mentioned θa1 is 5.0 degrees or more and 20.0 degrees or less.

[0061]

[19] An optical laminate as described in

[17] or

[18] , wherein the aforementioned θa2 is less than 10.0 degrees.

[0062]

[20] The optical laminate as described in

[17] , wherein the Pa1 is 0.05 μm or more and 0.25 μm or less.

[0063]

[21] An optical laminate as described in

[17] or

[18] , wherein the Pa2 is 0.15 μm or less.

[0064]

[22] An optical laminate as described in any one of

[17] to

[21] , wherein when the substrate side of the first resin layer from the center in the thickness direction is defined as a first region and the second resin layer side of the first resin layer from the center in the thickness direction is defined as a second region, more than 70% of the region α1 exists in the second region.

[0065]

[23] An optical laminate as described in any one of

[17] to

[22] , wherein the resin contained in the region α1 is substantially the same as the resin contained in the region β2, and the resin contained in the region α2 is substantially the same as the resin contained in the region β1.

[0066]

[24] An optical laminate as described in any one of

[17] to

[23] , wherein the resin layer comprises a first particle with an average particle size of 0.5 μm or more.

[0067]

[25] The optical laminate as described in

[24] , wherein the second resin layer comprises the first particle.

[0068]

[26] An optical laminate as described in

[24] or

[25] , wherein the first particle is an organic particle.

[0069]

[27] An optical laminate as described in any one of

[17] to

[26] , wherein the substrate is an acrylic resin substrate.

[0070]

[28] An optical laminate as described in any one of

[17] to

[27] , wherein the resin layer comprises a cured product of a curable resin composition.

[0071]

[29] A polarizer having a polarizing element, a first transparent protective plate disposed on one side of the polarizing element, and a second transparent protective plate disposed on the other side of the polarizing element, wherein at least one of the first transparent protective plate and the second transparent protective plate is any anti-glare laminate or optical laminate selected from the anti-glare laminates described in [1] to

[16] and the optical laminates described in

[17] to

[28] .

[0072]

[30] An image display device having on a display element any one of the anti-glare laminates or optical laminates selected from those described in [1] to

[16] and

[17] to

[28] .

[0073]

[31] The image display device as described in

[30] , wherein the image display device is a foldable image display device or a rollable image display device, and the display element has an anti-glare laminate as described in any one of [1] to

[16] .

[0074] The effects of the invention

[0075] The anti-glare laminate of the present invention improves pencil hardness and flexural strength. The polarizer and image display device of the present invention possess an anti-glare laminate with excellent pencil hardness and flexural strength, thus increasing the design freedom of the polarizer and image display device.

[0076] The optical laminate, polarizer, and image display device of the present invention can suppress the decrease in adhesion and the change in the clarity of the transmitted image after the lightfastness test. Attached Figure Description

[0077] Figure 1 This is a cross-sectional view showing one embodiment of the anti-glare laminate according to the first embodiment of the present invention.

[0078] Figure 2 This is a cross-sectional view showing the anti-glare laminates of Comparative Examples 1-3.

[0079] Figure 3 This is a cross-sectional view showing the anti-glare laminates of Comparative Examples 1-4.

[0080] Figure 4This is a cross-sectional view illustrating one embodiment of the image display device of the present invention.

[0081] Figure 5 This is a cross-sectional view showing one embodiment of the anti-glare laminate according to the second embodiment of the present invention.

[0082] Figure 6 This is a cross-sectional view showing the anti-glare laminate of Comparative Example 2-2.

[0083] Figure 7 This is a cross-sectional view illustrating one embodiment of the image display device of the present invention.

[0084] Figure 8 This is a cross-sectional view illustrating one embodiment of the optical laminate of the present invention.

[0085] Figure 9 This is a diagram illustrating the method for calculating the position of region α1 in the thickness direction of the first resin layer of the optical laminate.

[0086] Figure 10 This is a cross-sectional view illustrating one embodiment of the image display device of the present invention. Detailed Implementation

[0087] The embodiments of the present invention will be described below.

[0088] [Anti-glare laminate according to the first embodiment]

[0089] The anti-glare laminate of the first embodiment of the present invention has a resin layer on a substrate.

[0090] The resin layer described above has a first resin layer and a second resin layer from the substrate side.

[0091] The aforementioned resin layer contains a first particle with an average particle size of 0.5 μm or more.

[0092] More than 70% of the aforementioned first particles exist across the aforementioned first resin layer and the aforementioned second resin layer.

[0093] The anti-glare laminate satisfies the following equation 1.

[0094] 5.0 < t1 / t2 < 15.0 (Equation 1)

[0095] [In Formula 1, t1 represents the average thickness of the first resin layer, and t2 represents the average thickness of the second resin layer.]

[0096] Figure 1 This is a cross-sectional view showing one embodiment of the anti-glare laminate 100A according to the first embodiment of the present invention.

[0097] Figure 1 The anti-glare laminate 100A has a resin layer 20A on the substrate 10. Additionally, Figure 1 The resin layer 20A has a first resin layer 21A and a second resin layer 22A extending from the substrate 10 side. Additionally, Figure 1 The resin layer 20A contains first particles 23A with an average particle size of 0.5 μm or more. Additionally, Figure 1 The first particle 23A exists across the first resin layer 21A and the second resin layer 22A.

[0098] It should be noted that, Figure 1 It is a schematic cross-sectional view. That is, the scale of each layer, each material, and the surface unevenness of the anti-glare laminate 100A are schematic for ease of illustration and are different from the actual scale. Figure 1 The maps outside of this area also differ from the actual scale.

[0099] <Substrate>

[0100] As a substrate, good light transmittance, smoothness, heat resistance, and mechanical strength are preferred. Examples of such substrates include resin substrates containing resins such as polyester, triacetyl cellulose (TAC), cellulose diacetate, cellulose acetate butyrate, polyamide, polyimide, polyethersulfone, polysulfone, polypropylene, polymethylpentene, polyvinyl chloride, polyvinyl acetal, polyetherketone, acrylic resins, polycarbonate, polyurethane, and amorphous olefins (Cyclo-Olefin-Polymer: COP). The resin substrate can be formed by laminating two or more resin substrates together.

[0101] To improve mechanical strength and dimensional stability, it is preferable to perform a stretching treatment on the resin substrate.

[0102] Among resin substrates, acrylic resin substrates are preferred because they readily improve dimensional stability due to low hygroscopicity and readily improve visibility due to low optical anisotropy. Furthermore, by using a coating liquid with a predetermined composition and setting predetermined drying conditions, acrylic resin substrates allow for the easy formation of the first and second resin layers in a single coating step.

[0103] Acrylic resin substrates are hard and brittle, so if a resin layer containing a cured resin composition is formed on an acrylic resin substrate, the bending resistance sometimes becomes insufficient. The anti-glare laminate of the present invention, even when a resin layer containing a cured resin composition is formed on an acrylic resin substrate, can easily suppress the decrease in bending resistance by ensuring that the first particle is present at a predetermined position in the thickness direction of the resin layer and by satisfying Formula 1, etc.

[0104] In this specification, acrylic resins refer to acrylic resins and / or methacrylic resins.

[0105] There are no particular limitations on the acrylic resin contained in the acrylic resin base material. For example, acrylic resins polymerized by combining one or more alkyl (meth)acrylates are preferred. More specifically, acrylic resins obtained by using methyl (meth)acrylate are preferred. Examples of acrylic resins include those described in Japanese Patent Application Publication Nos. 2000-230016, 2001-151814, 2002-120326, 2002-254544, and 2005-146084. As acrylic resins, acrylic resins with cyclic structures, such as those having a lactone ring structure or an imide ring structure, can be used.

[0106] The glass transition temperature (Tg) of acrylic resin is preferably 100°C or higher and 150°C or lower, more preferably 105°C or higher and 135°C or lower, and even more preferably 110°C or higher and 130°C or lower.

[0107] If the glass transition temperature of the acrylic resin is above 100°C, excessive dissolution of the acrylic resin substrate can be easily suppressed during resin layer formation. If the glass transition temperature of the acrylic resin is below 150°C, the degree of dissolution of the acrylic resin substrate during resin layer formation can be easily controlled.

[0108] The acrylic resin substrate may include resins other than acrylic resins, and the proportion of acrylic resins relative to the total resins constituting the acrylic resin substrate is preferably 80% by mass or more, more preferably 90% by mass or more, and even more preferably 95% by mass or more.

[0109] Acrylic resin substrates can be manufactured, for example, by melting and extruding granules made of conditioned acrylic resin, then stretching them longitudinally while cooling, and then stretching them transversely.

[0110] In the melt extrusion process, single-shaft, twin-shaft, or twin-shaft screws can be used, and the screw rotation direction, speed, and melt temperature can be set arbitrarily.

[0111] The stretching is preferably performed in a manner that achieves the desired thickness after stretching. Furthermore, the stretching ratio is not limited, but is preferably 1.2 to 4.5 times. The temperature and humidity during stretching can be arbitrarily determined. Conventional methods can be used.

[0112] The average thickness of the substrate is preferably 10 μm or more, more preferably 20 μm or more, and even more preferably 35 μm or more. By making the average thickness of the substrate 10 μm or more, the operability of the anti-glare laminate can be easily improved.

[0113] The average thickness of the substrate is preferably 100 μm or less, more preferably 80 μm or less, and even more preferably 60 μm or less. By making the average thickness of the substrate 100 μm or less, the bending resistance of the anti-glare laminate can be easily improved.

[0114] Examples of preferred ranges for the average thickness of the substrate include 10 μm to 100 μm, 10 μm to 80 μm, 10 μm to 60 μm, 20 μm to 100 μm, 20 μm to 80 μm, 20 μm to 60 μm, 35 μm to 100 μm, 35 μm to 80 μm, and 35 μm to 60 μm.

[0115] The average thickness of the substrate mentioned above refers to the average thickness of the substrate when the anti-glare laminate is completed. As described later, by dissolving a portion of the substrate using the coating liquid for the resin layer, the average thickness of the substrate when the anti-glare laminate is completed may sometimes be less than the average thickness of the initial substrate. Therefore, the average thickness of the initial substrate is preferably thicker than the average thickness of the substrate when the anti-glare laminate is completed. The difference between the average thickness of the initial substrate and the average thickness of the substrate when the anti-glare laminate is completed varies depending on the thickness of the resin layer, the composition of the coating liquid for the resin layer, the drying conditions of the coating liquid, etc., and therefore cannot be generalized. Preferably, it is 0.1 μm to 10 μm, more preferably 1 μm to 5 μm.

[0116] The average thickness of the substrate can be calculated, for example, by selecting 20 points at any location in a cross-sectional photograph of the anti-glare laminate taken using a scanning transmission electron microscope (STEM) and calculating the average value. The accelerating voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification of the STEM is preferably 1000x or more and 7000x or less.

[0117] To determine the average thickness of the substrate, the thickness of the first resin layer, the thickness of the second resin layer, the position of the first particle in the thickness direction of the resin layer, the average tilt angle of the resin layer side surface of the substrate, and the arithmetic mean height of the resin layer side surface of the substrate, it is necessary to prepare a sample for measuring the cross-sectional exposure of the anti-glare laminate. This sample can be prepared, for example, by the steps (A1) to (A2) described later. It should be noted that, in cases where the interface is difficult to see due to insufficient contrast, the sample can be pretreated with osmium tetroxide, ruthenium tetroxide, phosphotungstic acid, etc.

[0118] In this specification, unless otherwise specified, the atmosphere for performing various measurements and evaluations, as well as for sampling used in these measurements and evaluations, is set to a temperature of 23±5°C and a relative humidity of 40% to 65%. Furthermore, before performing the measurements, evaluations, and sampling, the anti-glare laminate subject to the test is exposed to the aforementioned atmosphere for at least 30 minutes. This atmosphere is common to the anti-glare laminate of the first embodiment, the anti-glare laminate of the second embodiment, and the optical laminate.

[0119] The substrate is preferably one in which the average tilt angle of the surface of the resin layer side is 5.0 degrees or more and 15.0 degrees or less.

[0120] By setting the average tilt angle to 5 degrees or more, the flexural resistance of the anti-glare laminate can be easily further improved. The reason for the improved flexural resistance is believed to be due to the better adhesion between the substrate and the resin layer, preventing interfacial delamination during bending.

[0121] By keeping the average tilt angle below 15 degrees, it is easy to suppress the increase in internal haze. Furthermore, in the embodiment where a portion of the substrate is dissolved by the coating liquid in the resin layer, keeping the average tilt angle below 15 degrees makes it easy to improve pencil hardness. The reason for easily improving pencil hardness in the above embodiments is believed to be that, since the substrate components do not excessively dissolve into the resin layer, the hardness of the resin layer is difficult to reduce.

[0122] The average tilt angle of the substrate is more preferably 5.5 degrees or more, and even more preferably 6.0 degrees or more. The average tilt angle of the substrate is more preferably 14.0 degrees or less, and even more preferably 13.0 degrees or less.

[0123] Examples of preferred ranges for the average tilt angle of the substrate include 5.0 degrees to 15.0 degrees, 5.0 degrees to 14.0 degrees, 5.0 degrees to 13.0 degrees, 5.5 degrees to 15.0 degrees, 5.5 degrees to 14.0 degrees, 5.5 degrees to 13.0 degrees, 6.0 degrees to 15.0 degrees, 6.0 degrees to 14.0 degrees, and 6.0 degrees to 13.0 degrees.

[0124] The average tilt angle and arithmetic mean height of the substrate can be determined, for example, as follows.

[0125] (1) Take cross-sectional photographs of the anti-glare laminate using a scanning transmission electron microscope (STEM). The accelerating voltage of the STEM is preferably above 10kV and below 30kV, and the magnification of the STEM is preferably above 5000x and below 10000x.

[0126] (2) Obtain the edge line of the interface between the substrate and the resin layer from the cross-sectional photograph, and obtain the height data. Specifically, as shown in (a) to (l) below. The interface between the substrate and the resin layer corresponds to the surface of the resin layer side of the substrate.

[0127] (a) Display the captured images as ImageJ (version 1.52a), an open-source image processing software, in the public domain.

[0128] (b) Calculate the length of each pixel based on the scale displayed in the image.

[0129] (c) Select “FreeHand Selections” to create ROIs that include the interface, adjust the brightness, and make the colors distinctly different with the interface as the boundary.

[0130] (d) Perform Process-Smooth twice.

[0131] (e) Set Image-Type to 8-bit.

[0132] (f) Select “Straight” and draw a line along the interface.

[0133] (g) Import the ImageJ plugin ABSnake to execute. Here, set the "Gradient threshold" to 10 and the draw color to red. Keep other settings at their defaults.

[0134] (h) Visually confirm that the interface can be traced using Red. In case of problems, repeat from (f).

[0135] (i) Perform Image-Adjust-Color Threshold. Set the threshold to distinguish between Red and other colors. Specifically, set the color space to RGB, check the "Pass" for "Red", "Green" and "Blue", set the upper and lower limits of the Red range to the maximum value (255), and set the upper and lower limits of the "Green" and "Blue" ranges to the minimum value (0).

[0136] (j) Execute Process-Binary-Make Binary to binarize the part of the interface with the trace lines and the part outside the trace lines.

[0137] (k) Save the binarized data as “Text Image” in File-Save As.

[0138] (l) The interface is converted into a series of height data points from the binarized data.

[0139] (3) Based on the height data points, calculate the average tilt angle and arithmetic mean height according to the following steps (m) to (q).

[0140] (m) The centerline of the height data is obtained through quadratic regression using the least squares method and then subtracted from the height data, thus converting it to a value of 0 for the centerline, positive for the upward direction, and negative for the downward direction. The direction of the centerline is set as the x-axis, and the direction perpendicular to it (the height direction) is set as the y-axis.

[0141] (n) Use the length of each pixel obtained in (b) to convert the height data into length.

[0142] (o) Apply a Gaussian-based low-pass filter with a cutoff wavelength of 0.5 μm.

[0143] (p) Calculate the result from tan -1 ((y i+1 -y i-1 ) / 2Δx)[y i Let be the height of the i-th point in the height data point series, and Δx be the distance between adjacent points along the x-axis. Calculate the arithmetic mean of the absolute values ​​of the tilt angles of each point, and then calculate the average tilt angle.

[0144] (q) Calculate the arithmetic mean of the absolute values ​​of the heights of each point, and then obtain the arithmetic mean height.

[0145] The substrate is preferably one in which the arithmetic mean height of the surface of the resin layer side is 0.05 μm or more and 0.25 μm or less.

[0146] By achieving an arithmetic mean height of 0.05 μm or higher, the flexural strength of the anti-glare laminate can be easily improved. The improved flexural strength is attributed to the enhanced adhesion between the substrate and the resin layer, preventing interfacial delamination during bending.

[0147] By keeping the arithmetic mean height below 0.25 μm, the increase in internal haze can be easily suppressed. Furthermore, in the embodiment where a portion of the substrate is dissolved by the coating liquid in the resin layer, keeping the arithmetic mean height below 0.25 μm easily improves pencil hardness. The reason for easily improving pencil hardness in the above embodiments is believed to be that, since the substrate components do not excessively dissolve into the resin layer, the hardness of the resin layer is difficult to decrease.

[0148] The arithmetic mean height of the substrate is more preferably 0.07 μm or more, and even more preferably 0.09 μm or more. The arithmetic mean height of the substrate is more preferably 0.23 μm or less, and even more preferably 0.20 μm or less.

[0149] Examples of preferred ranges for the arithmetic mean height of the substrate include 0.05 μm to 0.25 μm, 0.05 μm to 0.23 μm, 0.05 μm to 0.20 μm, 0.07 μm to 0.25 μm, 0.07 μm to 0.23 μm, 0.07 μm to 0.20 μm, 0.09 μm to 0.25 μm, 0.09 μm to 0.23 μm, and 0.09 μm to 0.20 μm.

[0150] To ensure that the average tilt angle and arithmetic mean height of the resin layer side surface of the substrate are within the aforementioned range, it is preferable to dissolve a portion of the substrate with a resin layer coating solution. However, when dissolving the substrate with a resin layer coating solution, it is preferable to use a resin layer coating solution with a specified composition and to set specified drying conditions. The specified composition and specified drying conditions are described below.

[0151] The substrates of the anti-glare laminates and the optical laminates of the first and second embodiments may contain additives such as antioxidants, ultraviolet absorbers, light stabilizers, and plasticizers.

[0152] To improve adhesion, physical or chemical treatments such as corona discharge treatment can be applied to the surface of the substrate of the anti-glare laminate in the first and second embodiments, as well as the surface of the substrate of the optical laminate, or an easy-to-adhere layer can be formed.

[0153] <Resin Layer>

[0154] The resin layer needs to have a first resin layer and a second resin layer starting from the substrate side.

[0155] In addition, the first resin layer and the second resin layer need to satisfy the following formula 1.

[0156] 5.0 < t1 / t2 < 15.0 (Equation 1)

[0157] [In Equation 1, t1 represents the average thickness of the first resin layer, and t2 represents the average thickness of the second resin layer.]

[0158] The first and second resin layers can be formed, for example, by coating a resin layer coating solution containing the first particles, resin components, and solvent onto a substrate and then drying and curing as needed. The resin layer coating solution may also contain inorganic particles and additives as needed.

[0159] In the above method, a portion of the substrate is dissolved by the resin coating liquid, and the area formed by the mixture of the components dissolved from the substrate and the resin coating liquid becomes the first resin layer, while the area containing almost no components dissolved from the substrate and mainly composed of the resin coating liquid becomes the second resin layer. That is, in the above method, the first resin layer and the second resin layer can be formed by using one coating of a resin coating liquid.

[0160] In the above method, it is important that the resin layer is coated with a specific composition and that the drying conditions are specified. The specified composition and drying conditions are described below.

[0161] There are no particular limitations on the method of applying a resin layer to a substrate using a coating liquid. Common coating methods include spin coating, dip coating, spray coating, mold coating, bar coating, gravure coating, roller coating, meniscus coating, flexographic printing, screen printing, and droplet coating.

[0162] When curing the resin layer with a coating liquid, it is preferable to irradiate it with ionizing rays such as ultraviolet light and electron beams. Specific examples of ultraviolet light sources include ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black fluorescent lamps, and metal halide lamps. Furthermore, the wavelength of the ultraviolet light is preferably in the wavelength range of 190 nm to 380 nm. Specific examples of electron beam sources include various electron beam accelerators such as Cockcroft-Walton type, van der Graff type, resonant transformer type, insulated core transformer type, linear type, Dynamitron type, and high-frequency type.

[0163] It should be noted that, as a method for forming two resin layers, the method described in Comparative Examples 1-3 and 1-4 below, which involves preparing two coating solutions for resin layers, forming the first resin layer, and then laminating the second resin layer, is considered. However, when the coating solution for the first layer contains particles, it is difficult to improve the anti-glare performance; when the coating solution for the second layer contains particles, it is difficult to improve the flexural strength. Furthermore, in the method of forming two resin layers using two different coating solutions, it is difficult to improve the adhesion between the first and second layers.

[0164] Therefore, it is preferable to form the first resin layer and the second resin layer by using a single coating of a resin layer coating liquid, as described above.

[0165] When the resin layer is a single layer, it is difficult to improve the flexural strength or pencil hardness of the anti-glare laminate. For example, when the resin layer is a single layer with high hardness, it is difficult to improve the flexural strength of the anti-glare laminate. Furthermore, when the resin layer is a single layer with low hardness, it is difficult to improve the pencil hardness of the anti-glare laminate.

[0166] Furthermore, even if the resin layer has a first resin layer and a second resin layer, the flexural strength or pencil hardness of the anti-glare laminate cannot be improved if Formula 1 is not satisfied. The second resin layer is farther from the substrate than the first resin layer, therefore, the second resin layer contains less of the components leached from the substrate. Consequently, the hardness of the second resin layer is more likely to be higher than that of the first resin layer. A t1 / t2 ratio of 15.0 or higher means that the proportion of the second resin layer with higher hardness is small. Therefore, when t1 / t2 is 15.0 or higher, the pencil hardness of the anti-glare laminate cannot be improved. Conversely, a t1 / t2 ratio of 5.0 or lower means that the proportion of the second resin layer with higher hardness is large. Therefore, when t1 / t2 is 5.0 or lower, the flexural strength of the anti-glare laminate cannot be improved.

[0167] The ratio t1 / t2 is preferably 5.5 or more, more preferably 6.0 or more. Furthermore, the ratio t1 / t2 is preferably 14.0 or less, more preferably 13.5 or less.

[0168] Examples of preferred ranges for t1 / t2 include values ​​greater than 5.0 and less than 15.0, greater than 5.0 and less than 14.0, greater than 5.0 and less than 13.5, greater than 5.5 and less than 15.0, greater than 5.5 and less than 14.0, greater than 5.5 and less than 13.5, greater than 6.0 and less than 15.0, greater than 6.0 and less than 14.0, and greater than 6.0 and less than 13.5.

[0169] The lower limit of the overall thickness of the resin layer (in other words, the total thickness of the first resin layer and the second resin layer) is preferably 7.0 μm or more, more preferably 8.0 μm or more, and even more preferably 9.0 μm or more, and the upper limit is preferably 15.0 μm or less, more preferably 14.0 μm or less, and even more preferably 13.0 μm or less.

[0170] Examples of preferred ranges for the overall thickness of the resin layer include 7.0 μm to 15.0 μm, 7.0 μm to 14.0 μm, 7.0 μm to 13.0 μm, 8.0 μm to 15.0 μm, 8.0 μm to 14.0 μm, 8.0 μm to 13.0 μm, 9.0 μm to 15.0 μm, 9.0 μm to 14.0 μm, and 9.0 μm to 13.0 μm.

[0171] The lower limit of the average thickness t1 of the first resin layer is preferably 5.0 μm or more, more preferably 7.0 μm or more, and even more preferably 8.5 μm or more, and the upper limit is preferably 13.0 μm or less, more preferably 12.0 μm or less, and even more preferably 11.0 μm or less. By making t1 5.0 μm or more, the bending resistance can be easily improved, and by making t1 13.0 μm or less, the decrease in pencil hardness can be easily suppressed.

[0172] Examples of preferred ranges for t1 include 5.0 μm to 13.0 μm, 5.0 μm to 12.0 μm, 5.0 μm to 11.0 μm, 7.0 μm to 13.0 μm, 7.0 μm to 12.0 μm, 7.0 μm to 11.0 μm, 8.5 μm to 13.0 μm, 8.5 μm to 12.0 μm, and 8.5 μm to 11.0 μm.

[0173] The lower limit of the average thickness t2 of the second resin layer is preferably 0.3 μm or more, more preferably 0.5 μm or more, and even more preferably 0.7 μm or more, and the upper limit is preferably 4.0 μm or less, more preferably 3.0 μm or less, and even more preferably 2.7 μm or less. By making t2 0.3 μm or more, the pencil hardness can be easily improved, and by making t2 4.0 μm or less, the reduction in bending resistance can be easily suppressed.

[0174] Examples of preferred ranges for t2 include 0.3μm to 4.0μm, 0.3μm to 3.0μm, 0.3μm to 2.7μm, 0.5μm to 4.0μm, 0.5μm to 3.0μm, 0.5μm to 2.7μm, 0.7μm to 4.0μm, 0.7μm to 3.0μm, and 0.7μm to 2.7μm.

[0175] The average thickness of the first resin layer and the average thickness of the second resin layer can be calculated, for example, by selecting 20 points at any location in a cross-sectional photograph of the anti-glare laminate taken using a scanning transmission electron microscope (STEM) and calculating their average values. The accelerating voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification of the STEM is preferably 1000x or more and 7000x or less.

[0176] The resin layer needs to contain a first particle with an average particle size of 0.5 μm or more.

[0177] Anti-glare properties cannot be imparted to anti-glare laminates if the resin layer does not contain the first particle.

[0178] The resin layer needs to have more than 70% of the first particle number spanning across the first and second resin layers.

[0179] The existence of the first particle 23A spanning the first resin layer 21A and the second resin layer 22A means that, as Figure 1 As shown, in the thickness direction of resin layer 20A, the first particle 23A exists on both sides of the first resin layer 21A and the second resin layer 22A. On the other hand, Figure 2 In this process, the first particle 23A does not exist across the first resin layer 21A and the second resin layer 22A, but exists on only one side of the second resin layer 22A. Figure 3 In this process, the first particle 23A does not exist across the first resin layer 21A and the second resin layer 22A, but exists on only one side of the first resin layer 21A.

[0180] In this specification, "more than 70% of the number of the first particle spans the first resin layer and the second resin layer" is sometimes referred to as "the condition that the first particle satisfies the position in the thickness direction". In this specification, "more than 70% of the number of the first particle does not span the first resin layer and the second resin layer" is sometimes referred to as "the condition that the first particle does not satisfy the position in the thickness direction".

[0181] If the position of the first particle does not meet the requirements in the thickness direction, the anti-glare and bending resistance cannot be improved.

[0182] When the first particle does not meet the condition of being positioned in the thickness direction, more than 30% of the first particles, based on the number of particles, exist in either the first or second resin layer without crossing the first and second resin layers. In this specification, the first particles that exist in either the first or second resin layer without crossing the first and second resin layers are sometimes referred to as "biased first particles". When a large number of biased first particles are present in the first resin layer, it is difficult to form an uneven surface on the resin layer through the first particles, thus failing to improve anti-glare performance. In addition, when the anti-glare laminate is bent, peeling sometimes occurs at the interface between the first particle and the resin layer, which reduces the bending resistance. The harder the resin layer, the more difficult it is to suppress peeling at the interface between the first particle and the resin layer. Therefore, when a large number of biased first particles are present in the second resin layer, the bending resistance cannot be improved.

[0183] The proportion of the first particle present on both sides of the first resin layer and the second resin layer in the thickness direction of the resin layer is preferably 80% or more, more preferably 90% or more, based on the number of particles.

[0184] The location of the first particle in the thickness direction of the resin layer can be determined, for example, by using a cross-sectional photograph of the anti-glare laminate taken with a scanning transmission electron microscope (STEM). Furthermore, the proportion of the aforementioned number reference can be calculated from the cross-sectional photograph. It should be noted that, to improve the reliability of the values, it is preferable to obtain multiple cross-sectional photographs, set the total number of the first particle to 50 or more, and then calculate the proportion of the aforementioned number reference.

[0185] The preferred accelerating voltage for STEM is above 10kV and below 30kV, and the preferred STEM magnification is above 1000 times and below 7000 times.

[0186] The indentation hardness H1, which represents the center of the thickness direction of the first resin layer, and the indentation hardness H2, which represents the center of the thickness direction of the second resin layer, are preferably in a relationship of H1 < H2.

[0187] By satisfying the relationship H1 < H2, the hardness and bending resistance of anti-glare laminated pencils can be easily improved.

[0188] H1 and H2 are preferably 40 MPa < H2-H1. By making H2-H1 exceed 40 MPa, the pencil hardness and flexural strength of the anti-glare laminate can be easily improved. H2-H1 is more preferably 45 MPa or more, and even more preferably 50 MPa or more.

[0189] When H2-H1 is too large, the bending resistance of the anti-glare laminate is easily reduced due to the excessively large H2, or the pencil hardness of the anti-glare laminate is easily reduced due to the excessively small H1. Therefore, H2-H1 is preferably 100 MPa or less, more preferably 90 MPa or less, and even more preferably 80 MPa or less.

[0190] The value of H2 can be adjusted by the resin components of the coating liquid constituting the resin layer. The value of H1 is the mixture of the resin components of the coating liquid constituting the resin layer and the components dissolved from the substrate, and therefore can be adjusted by the two components mentioned above.

[0191] Examples of preferred ranges for H2-H1 include: more than 40 MPa and less than 100 MPa, more than 40 MPa and less than 90 MPa, more than 40 MPa and less than 80 MPa, more than 45 MPa and less than 100 MPa, more than 45 MPa and less than 90 MPa, more than 45 MPa and less than 80 MPa, more than 50 MPa and less than 100 MPa, more than 50 MPa and less than 90 MPa, and more than 50 MPa and less than 80 MPa.

[0192] To facilitate the improvement of pencil hardness, the lower limit of H1 is preferably 150 MPa or more, more preferably 160 MPa or more, and even more preferably 170 MPa or more. To facilitate the suppression of the decrease in bending resistance, the upper limit is preferably 250 MPa or less, more preferably 240 MPa or less, and even more preferably 230 MPa or less.

[0193] Examples of preferred ranges for H1 include 150 MPa to 250 MPa, 150 MPa to 240 MPa, 150 MPa to 230 MPa, 160 MPa to 250 MPa, 160 MPa to 240 MPa, 160 MPa to 230 MPa, 170 MPa to 250 MPa, 170 MPa to 240 MPa, and 170 MPa to 230 MPa.

[0194] To facilitate the improvement of pencil hardness, the lower limit of H2 is preferably 230 MPa or more, more preferably 240 MPa or more, and even more preferably 245 MPa or more. To facilitate the suppression of the decrease in bending resistance, the upper limit is preferably 310 MPa or less, more preferably 290 MPa or less, and even more preferably 285 MPa or less.

[0195] Examples of preferred ranges for H2 include 230 MPa to 310 MPa, 230 MPa to 290 MPa, 230 MPa to 285 MPa, 240 MPa to 310 MPa, 240 MPa to 290 MPa, 240 MPa to 285 MPa, 245 MPa to 310 MPa, 245 MPa to 290 MPa, and 245 MPa to 285 MPa.

[0196] -Methods for determining indentation hardness-

[0197] To determine H1 to H3, it is necessary to prepare a sample for measurement, showing the cross-sectional exposure of the layer to be measured. This sample can be prepared, for example, by the steps (A1) to (A2) described below.

[0198] (A1) After preparing cut samples of the anti-glare laminate to any size, prepare embedded samples by embedding the cut samples in resin. The size of the cut samples is, for example, a strip 10 mm long × 3 mm wide. Epoxy resin is preferred for embedding.

[0199] An embedded sample can be obtained, for example, by placing a cut sample inside a silicon embedding plate, allowing the resin for embedding to flow in, then curing the resin, and finally removing the cut sample and the resin encapsulating it from the silicon embedding plate. In the case of the epoxy resin manufactured by Struers, as exemplified below, the above curing process is preferably carried out by leaving it at room temperature for 12 hours. The embedded sample is in block shape.

[0200] Examples of silicone embedding plates include those manufactured by Dosaka Em. Silicon embedding plates are sometimes also called silicone capsules. The epoxy resin used for embedding can be, for example, a mixture of Struers' trade name "EpoFix" and its trade name "EpoFix Curing Agent" in a 10:1.2 ratio.

[0201] (A2) The block-shaped embedded sample is vertically cut to create a sample for measuring the indentation hardness of the exposed cross-section of the anti-glare laminate. The sample for measuring the indentation hardness is kept in a block shape. The embedded sample is preferably cut by cutting through the center of the sample. The embedded sample is preferably cut with a diamond cutter.

[0202] As an apparatus for cutting block-shaped embedded samples, an example is the "Ultra Microtome EMUC7" manufactured by Leica Microsystems. When cutting block-shaped embedded samples, it is preferable to initially make a rough cut (coarse trimming) and then finally trim it precisely under the conditions of "speed: 1.00 mm / s" and "feed: 70 nm".

[0203] As described above, uniform slices cut from block-shaped embedded samples that are free of defects such as pores and have a thickness of 60 nm to 100 nm can be used as samples for measuring the average thickness of the first resin layer, the average thickness of the second resin layer, the position of the first particle in the thickness direction of the resin layer, the average tilt angle of the surface of the resin layer side of the substrate, the arithmetic mean height of the surface of the resin layer side of the substrate, the particle size of the first particle, and the particle size of inorganic particles.

[0204] H1 to H3 are measured by vertically pressing a Berkovich indenter (material: diamond triangular pyramid) into a specified position on the cut surface of the above samples.

[0205] Regarding the specified location, in the measurement of H1, it is the exact center in the thickness direction of the first resin layer; in the measurement of H2, it is the exact center in the thickness direction of the second resin layer; and in the measurement of H3, it is the exact center in the thickness direction of the substrate. The exact center in the thickness direction of the first resin layer is preferably the center of the first resin layer, but an offset of 0.10 μm from this center is permissible. Similarly, the exact center in the thickness direction of the second resin layer is preferably the center of the second resin layer, but an offset of 0.10 μm from this center is permissible. Likewise, the exact center in the thickness direction of the substrate is preferably the center of the substrate, but an offset of 0.10 μm from this center is permissible.

[0206] Indentation hardness is preferably measured under the following conditions.

[0207] <Measurement Conditions>

[0208] • Indenter used: Berkovich indenter (model: TI-0039, manufactured by BRUKER)

[0209] • Pressing conditions: Load control method

[0210] Maximum load: 50μN

[0211] • Load application time: 10 seconds (load change rate: 5 μN / sec)

[0212] • Duration: 5 seconds

[0213] • Holding load: 50μN

[0214] • Load unloading time: 10 seconds (load change rate: -5μN / sec)

[0215] The indentation hardness can be calculated as follows.

[0216] First, load-displacement curves are generated by continuously measuring the indentation depth h (nm) corresponding to the indentation load F (N). The generated load-displacement curves are then analyzed to determine the maximum indentation load F. max (N) divided by the projected area A of the indenter in contact with the object being measured. p (mm 2 The obtained value can be used to calculate the indentation hardness H. IT (Formula 2 below).

[0217] H IT =F max / A p (Equation 2)

[0218] Here, A pThe contact projected area of ​​the indenter tip curvature was corrected using the Oliver-Pharr method with fused silica (5-0098 manufactured by BRUKER) as a standard sample.

[0219] In this instruction manual, H1 to H3 refer to the average values ​​of the measured values ​​of 20 samples.

[0220] The First Particle

[0221] The first particle consists of particles with an average particle size of 0.5 μm or larger. If the average particle size is less than 0.5 μm, it is difficult to form an uneven shape on the surface of the resin layer, thus failing to improve the anti-glare performance.

[0222] Examples of the first particle include organic particles formed from one or more resins selected from polymethyl methacrylate, polyacrylic acid-styrene copolymer, melamine resin, polycarbonate, polystyrene, polyvinyl chloride, benzoguanamine-melamine-formaldehyde condensate, organosilicon, fluorinated resin, and polyester resin; and inorganic particles formed from one or more inorganic substances selected from silica, alumina, zirconium oxide, and titanium dioxide. Organic particles exhibit excellent dispersion stability and a relatively low specific gravity, making them preferred from the perspective of easily satisfying the positional requirements in the thickness direction.

[0223] The lower limit of the content of the first particle is preferably 0.5 parts by mass or more, more preferably 1.0 parts by mass or more, and even more preferably 1.5 parts by mass or more, and the upper limit is preferably 10.0 parts by mass or less, more preferably 5.0 parts by mass or less, and even more preferably 3.0 parts by mass or less, relative to 100 parts by mass of the resin component in the coating liquid for the resin layer.

[0224] By making the content of the first particle 0.5 parts by mass or more, the anti-glare property can be easily improved. In addition, by making the content of the first particle 10.0 parts by mass or less, the reduction in flexural strength can be easily suppressed.

[0225] Examples of preferred ranges for the content of the first particle relative to 100 parts by weight of resin include 0.5 parts by weight to 10.0 parts by weight, 0.5 parts by weight to 5.0 parts by weight, 0.5 parts by weight to 3.0 parts by weight, 1.0 parts by weight to 10.0 parts by weight, 1.0 parts by weight to 5.0 parts by weight, 1.0 parts by weight to 3.0 parts by weight, 1.5 parts by weight to 10.0 parts by weight, 1.5 parts by weight to 5.0 parts by weight, and 1.5 parts by weight to 3.0 parts by weight.

[0226] The average particle size of the first particle is preferably 0.8 μm or more, more preferably 1.0 μm or more.

[0227] In order to make it easy for the first particle to meet the positional conditions in the thickness direction, the average particle size of the first particle is preferably 3.0 μm or less, more preferably 2.7 μm or less, and even more preferably 2.5 μm or less.

[0228] Examples of preferred ranges for the average particle size of the first particle include 0.8 μm to 3.0 μm, 0.8 μm to 2.7 μm, 0.8 μm to 2.5 μm, 1.0 μm to 3.0 μm, 1.0 μm to 2.7 μm, and 1.0 μm to 2.5 μm.

[0229] The average particle size of the first particle can be calculated, for example, by the following operations (B1) to (B3).

[0230] (B1) Take a transmission observation image of the anti-glare laminate using an optical microscope. The magnification is preferably 500x or higher and 2000x or lower.

[0231] (B2) Extract any 10 particles from the observed image and calculate the particle size of each particle. The particle size is determined by the distance between the two lines that are the largest distance between them when the cross-section of the particle is held between any two parallel lines.

[0232] (B3) Perform the same operation 5 times in another image of the same sample, and use the average value obtained by the total of 50 particle sizes as the average particle size.

[0233] However, when the first particle cannot be observed optically, the average particle size of the first particle is calculated using (B4) to (B6) below.

[0234] (B4) A slice is made from the anti-glare laminate using a slicing machine, forming a cross-section passing through the center of the first particle. The thickness of the slice is preferably 60 nm to 100 nm. Multiple slices can be made continuously from one first particle, and the slice with the largest particle size calculated by the operation of (B5) is used as the cross-section passing through the center of the first particle.

[0235] (B5) The obtained slices are observed using a scanning transmission electron microscope (STEM), and the particle size is calculated. The calculation method for particle size is the same as in (B2). The preferred magnification is 5000x to 20000x.

[0236] (B6) Perform operations (B4) to (B5) on 20 particles, and take the average value obtained from the 20 particle sizes as the average particle size of the first particle.

[0237] The relationship between D1, which represents the average particle size of the first particle, and t2, which represents the average thickness of the second resin layer, is preferably t2 < D1. By setting t2 < D1, the surface of the anti-glare laminate can be easily given an uneven shape using the first particle, thus easily improving the anti-glare performance.

[0238] D1-t2 is preferably 0.5 μm or more, and more preferably 0.7 μm or more.

[0239] If D1-t2 is too large, the bending resistance may decrease because the first particle protrudes from the surface of the second resin layer. Therefore, D1-t2 is preferably 2.0 μm or less, more preferably 1.7 μm or less, and even more preferably 1.5 μm or less.

[0240] Examples of preferred ranges for D1-t2 include 0.5μm to 2.0μm, 0.5μm to 1.7μm, 0.5μm to 1.5μm, 0.7μm to 2.0μm, 0.7μm to 1.7μm, and 0.7μm to 1.5μm.

[0241] The relationship between D1, representing the average particle size of the first particle, and t1, representing the average thickness of the first resin layer, is preferably D1 < t1. By setting D1 < t1, it is easy to further improve the flexural resistance.

[0242] The t1-D1 is preferably 4.0 μm or more, more preferably 5.0 μm or more, and even more preferably 6.0 μm or more.

[0243] If t1-D1 is too large, the thickness of the first resin layer with low hardness increases, which sometimes reduces the pencil hardness. Therefore, t1-D1 is preferably 10.0 μm or less, more preferably 9.0 μm or less, and even more preferably 8.5 μm or less.

[0244] Examples of preferred ranges for t1-D1 include 5.0μm to 10.0μm, 5.0μm to 9.0μm, 5.0μm to 8.5μm, 6.0μm to 10.0μm, 6.0μm to 9.0μm, and 6.0μm to 8.5μm.

[0245] Inorganic Particles

[0246] The resin layer can contain inorganic microparticles. By including relatively heavy inorganic microparticles in the resin layer, the first particle is less likely to sink to the bottom of the resin layer, thus easily satisfying the positional requirements in the thickness direction. Furthermore, the inorganic microparticles improve the dispersibility of the first particle, effectively suppressing any decrease in flexural strength.

[0247] In this specification, inorganic microparticles refer to inorganic particles with an average primary particle size of less than 200 nm.

[0248] The average particle size of the inorganic microparticles is preferably 1 nm or more and 200 nm or less, more preferably 2 nm or more and 100 nm or less, and even more preferably 5 nm or more and 50 nm or less.

[0249] The average particle size of inorganic particles can be calculated using the following operations (C1) to (C3).

[0250] (C1) Take a cross-section of the anti-glare laminate using TEM or STEM. The accelerating voltage of the TEM or STEM is preferably 10kV or higher and 30kV or lower, and the magnification is preferably 50,000x or higher and 300,000x or lower.

[0251] (C2) Extract any 10 inorganic particles from the observed image and calculate the particle size of each inorganic particle. The particle size is determined by the distance between the two lines that are the largest distance between the two lines when the cross-section of the inorganic particle is held between any two parallel lines.

[0252] (C3) Perform the same operation 5 times in another image of the same sample, and use the average value obtained by the total of 50 particle sizes as the average particle size of the inorganic particles.

[0253] Examples of inorganic particles include those composed of silicon dioxide, aluminum oxide, zirconium oxide, and titanium dioxide. Among these, silicon dioxide is preferred as it readily suppresses the generation of internal haze.

[0254] The content of inorganic microparticles is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, and even more preferably 0.7 parts by mass or more, and the upper limit is preferably 5.0 parts by mass or less, more preferably 3.0 parts by mass or less, and even more preferably 2.0 parts by mass or less, relative to 100 parts by mass of the resin component in the coating liquid for the resin layer.

[0255] By making the content of inorganic microparticles 0.1 parts by mass or more, the first particle can easily meet the positional requirements in the thickness direction. Furthermore, by making the content of inorganic microparticles 5.0 parts by mass or less, the first particle can be prevented from excessively floating on top of the resin layer, thus the first particle can easily meet the positional requirements in the thickness direction.

[0256] Examples of preferred ranges for the content of inorganic particles relative to 100 parts by weight of resin include 0.1 to 5.0 parts by weight, 0.1 to 3.0 parts by weight, 0.1 to 2.0 parts by weight, 0.5 to 5.0 parts by weight, 0.5 to 3.0 parts by weight, 0.5 to 2.0 parts by weight, 0.7 to 5.0 parts by weight, 0.7 to 3.0 parts by weight, and 0.7 to 2.0 parts by weight.

[0257] Resin Composition

[0258] The resin layer preferably comprises a cured product of the curable resin composition as a resin component. By including a cured product of the curable resin composition in the resin layer, the pencil hardness of the anti-glare laminate can be easily improved. The cured product of the curable resin composition is preferably included in both the first resin layer and the second resin layer.

[0259] The ratio of the curable resin composition to the total amount of resin component in the coating liquid for the resin layer is preferably 80% by mass or more, more preferably 90% by mass or more, further preferably 95% by mass or more, and most preferably 100% by mass.

[0260] Examples of cured products of curable resin compositions include cured products of thermosetting resin compositions and cured products of ionizing radiation-curable resin compositions. Among these, cured products of ionizing radiation-curable resin compositions that readily increase pencil hardness and readily dissolve the substrate in the uncured state are preferred.

[0261] Thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that is cured by heating.

[0262] Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In thermosetting resin compositions, curing agents are added to these curing resins as needed.

[0263] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). Examples of ionizing radiation-curable functional groups include olefinic unsaturated groups such as (meth)acryloyl, vinyl, and allyl, as well as epoxy and oxetyl groups. Compounds having olefinic unsaturated groups are preferred as ionizing radiation-curable compounds.

[0264] Ionizing rays are electromagnetic waves or charged particle beams that contain energy quanta capable of polymerizing or cross-linking molecules. They are usually ultraviolet rays or electron rays. In addition, electromagnetic waves such as X-rays and gamma rays, as well as charged particle beams such as alpha rays and ion beams can also be used.

[0265] In this specification, (meth)acryloyl group means acryloyl group or methacryloyl group. Additionally, in this specification, (meth)acrylate means acrylate or methacrylate.

[0266] As an ionizing ray curable compound, either a monofunctional ionizing ray curable compound having one ionizing ray curable functional group or a polyfunctional ionizing ray curable compound having two or more ionizing ray curable functional groups can be used. Furthermore, either a monomer or an oligomer can be used as an ionizing ray curable compound.

[0267] To dissolve a portion of the substrate, increase pencil hardness, and easily suppress curing shrinkage, the mixture of (a) to (c) below is preferably used as the ionizing radiation curable compound. (a) to (c) below are preferably compounds having olefinic unsaturated bond groups as ionizing radiation curable functional groups, and more preferably (meth)acrylate compounds. (Meth)acrylate compounds can also be compounds obtained by modifying a portion of the molecular skeleton using ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl groups, cyclic alkyl groups, aromatic compounds, bisphenols, etc.

[0268] (a) Monofunctional ionizing radiation-curable monomer

[0269] (b) Multifunctional ionizing radiation-curable monomers

[0270] (c) Multifunctional ionizing radiation-cured oligomers

[0271] By using a monofunctional ionizing radiation-curable monomer containing (a) as the ionizing radiation-curable compound, a portion of the substrate can be easily dissolved, and the components dissolved from the substrate can be easily compatible with the components of the coating liquid for the resin layer. Furthermore, by using a monofunctional ionizing radiation-curable monomer containing (a), the viscosity of the coating liquid for the resin layer is reduced, thus facilitating convection between the coating liquid for the resin layer and the components dissolved from the substrate. As a result, the thickness of the first resin layer is greater than the thickness of the second resin layer, thus making it easier to exceed t1 / t2.

[0272] However, if the amount of the monofunctional ionizing radiation-curable monomer in (a) is excessive, it will over-dissolve the substrate, thus sometimes reducing the strength of the substrate or the pencil hardness of the anti-glare laminate. In addition, if the amount of the monofunctional ionizing radiation-curable monomer in (a) is excessive, the aforementioned convection becomes more intense, thus the thickness of the first resin layer becomes too large relative to the thickness of the second resin layer, sometimes t1 / t2 exceeds 15.

[0273] By using a multifunctional ionizing radiation-curable monomer containing (b) as an ionizing radiation-curable compound, the pencil hardness of the anti-glare laminate can be easily improved. However, if the amount of the multifunctional ionizing radiation-curable monomer (b) is too large, the hardness of the resin layer may become too high, and the bending resistance of the anti-glare laminate may decrease.

[0274] By using a multifunctional ionizing radiation-curable oligomer containing (c) as the ionizing radiation-curable compound, it is possible to easily suppress curing shrinkage while maintaining the pencil hardness of the anti-glare laminate. However, if the amount of the multifunctional ionizing radiation-curable oligomer containing (c) is too large, the pencil hardness of the anti-glare laminate may sometimes decrease.

[0275] Relative to the total amount of the ionizing radiation curable compound, the amount of the monofunctional ionizing radiation curable monomer of (a) is preferably 10% by mass or more and 40% by mass or less, more preferably 15% by mass or more and 35% by mass or less, and even more preferably 17% by mass or more and 33% by mass or less.

[0276] Relative to the total amount of the ionizing radiation curable compound, the amount of the multifunctional ionizing radiation curable monomer in (b) is preferably 5% by mass or more and 20% by mass or less, more preferably 6% by mass or more and 15% by mass or less, and even more preferably 7% by mass or more and 13% by mass or less.

[0277] Relative to the total amount of the ionizing radiation curable compound, (c) the amount of the multifunctional ionizing radiation curable oligomer is preferably 40% by mass or more and 80% by mass or less, more preferably 50% by mass or more and 77% by mass or less, and even more preferably 55% by mass or more and 75% by mass or less.

[0278] Examples of monofunctional ionizing radiation-curable monomers for (a) include methyl methacrylate, ethyl methacrylate, propyl methacrylate, butyl methacrylate, amyl methacrylate, hexyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, lauryl methacrylate, stearyl methacrylate, isobornyl methacrylate, 2-hydroxyethyl methacrylate, 4-hydroxybutyl methacrylate, and 2-hydroxypropyl methacrylate. Among these, monofunctional monomers with hydroxyl groups, such as 4-hydroxybutyl methacrylate, readily improve adhesion to the substrate and are therefore preferred.

[0279] Examples of difunctional ionizing radiation curable monomers among the multifunctional ionizing radiation curable monomers in (b) include ethylene glycol di(meth)acrylate, bisphenol A tetraethoxydiacrylate, bisphenol A tetrapropoxydiacrylate, and 1,6-hexanediol diacrylate. Examples of trifunctional or more functional ionizing radiation curable monomers include trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, dipentaerythritol tetra(meth)acrylate, and isocyanuric acid modified tri(meth)acrylate.

[0280] In order to increase pencil hardness while suppressing curing shrinkage, the number of functional groups of the multifunctional ionizing ray curable monomer in (b) is preferably 3 or more and 5 or less, more preferably 3 or more and 4 or less, and even more preferably 3.

[0281] Examples of multifunctional ionizing radiation-curable oligomers as (c) include urethane (meth)acrylates, epoxy (meth)acrylates, polyester (meth)acrylates, polyether (meth)acrylates, and other acrylate polymers.

[0282] Carbamate (meth)acrylates are obtained, for example, by reacting polyols and organic diisocyanates with hydroxy (meth)acrylates.

[0283] Preferred epoxy (meth)acrylates are (meth)acrylates obtained by reacting trifunctional or higher aromatic epoxy resins, alicyclic epoxy resins, and aliphatic epoxy resins with (meth)acrylate; (meth)acrylates obtained by reacting difunctional or higher aromatic epoxy resins, alicyclic epoxy resins, and aliphatic epoxy resins with polybasic acids and (meth)acrylate; and (meth)acrylates obtained by reacting difunctional or higher aromatic epoxy resins, alicyclic epoxy resins, and aliphatic epoxy resins with phenols and (meth)acrylate.

[0284] In order to maintain pencil hardness while suppressing curing shrinkage, the number of functional groups in the multifunctional ionizing ray curable oligomer of (c) is preferably 4 or more and 8 or less, more preferably 5 or more and 7 or less, and even more preferably 6.

[0285] In order to maintain pencil hardness while suppressing curing shrinkage, the weight average molecular weight of the multifunctional ionizing radiation curable oligomer of (c) is preferably 1,000 to 5,000, more preferably 1,100 to 3,500, and even more preferably 1,200 to 2,000.

[0286] In this specification, the weight-average molecular weight is the average molecular weight determined by GPC analysis and converted to standard polystyrene.

[0287] When the ionizing radiation curable compound is an ultraviolet curable compound, the ionizing radiation curable composition preferably contains additives such as photopolymerization initiators and photopolymerization accelerators.

[0288] As photopolymerization initiators, one or more can be selected from acetophenone, benzophenone, α-hydroxyalkyl phenyl ketone, michaelone, benzoin, benzyl dimethyl ketal, benzoylbenzoate, α-acyl oxime ester, thioxanone, etc.

[0289] Photopolymerization accelerators can reduce polymerization hindrance caused by air during curing, thereby accelerating the curing speed. Examples include one or more selected from p-dimethylaminobenzoate isoamyl ester, p-dimethylaminobenzoate ethyl ester, etc.

[0290] "additive"

[0291] The coating liquid for the resin layer can contain additives such as leveling agents, refractive index modifiers, antistatic agents, antifouling agents, ultraviolet absorbers, light stabilizers, antioxidants, viscosity modifiers, and thermal polymerization initiators, as needed.

[0292] Solvent

[0293] The coating liquid for the resin layer preferably contains a solvent.

[0294] As a solvent, it is preferable to choose a solvent that can dissolve the substrate. However, if the substrate is over-dissolved, the strength of the substrate will decrease, so it is preferable to select an appropriate solvent according to the type of substrate.

[0295] Furthermore, solvent selection considers not only the solubility in the substrate but also the inherent evaporation rate of the solvent. This is because a slow solvent evaporation rate can easily lead to over-dissolving of the substrate. The solvent evaporation rate can also be controlled by the drying conditions. For example, increasing the drying temperature accelerates the solvent evaporation rate. Additionally, increasing the drying air velocity also accelerates the solvent evaporation rate.

[0296] Therefore, solvents should be selected with consideration of the solubility of the substrate, evaporation rate, and drying conditions.

[0297] Examples of solvents include: ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ethers such as dioxane and tetrahydrofuran; aliphatic hydrocarbons such as hexane; alicyclic hydrocarbons such as cyclohexane; aromatic hydrocarbons such as toluene and xylene; carbon halogens such as dichloromethane and dichloroethane; esters such as methyl acetate, ethyl acetate, and butyl acetate; alcohols such as isopropanol, butanol, and cyclohexanol; cellosolves such as methyl cellosolve and ethyl cellosolve; glycol ethers such as propylene glycol monomethyl ether acetate; acetic acid cellosolves; sulfoxides such as dimethyl sulfoxide; and amides such as dimethylformamide and dimethylacetamide. Solvents can be a single solvent or a mixture of two or more solvents.

[0298] Acrylic resin substrates are readily soluble in solvents. Therefore, when using acrylic resin substrates, it is preferable to use a solvent with a fast evaporation rate as the main component. The main component refers to 50% by mass or more of the total solvent, preferably 70% by mass or more, more preferably 90% by mass or more, and most preferably 100% by mass.

[0299] In this specification, a solvent with a fast evaporation rate refers to a solvent with an evaporation rate of 100 or higher when the evaporation rate of butyl acetate is set to 100. More preferably, the evaporation rate of a solvent with a fast evaporation rate is 120 to 300, and even more preferably 140 to 220.

[0300] Examples of solvents with fast evaporation rates include isopropanol (evaporation rate 150), methyl isobutyl ketone (evaporation rate 160), and toluene (evaporation rate 200).

[0301] Drying conditions

[0302] When forming a resin layer from a resin layer using a coating liquid, it is preferable to control the drying conditions.

[0303] Drying conditions can be controlled by the drying temperature and the air velocity within the dryer. The preferred ranges for drying temperature and air velocity vary depending on the composition of the coating liquid for the resin layer, and therefore cannot be generalized. The preferred drying temperature is 85°C to 105°C, and the preferred air velocity is 5 m / s to 20 m / s. The preferred drying time is 30 seconds to 90 seconds. Drying temperature is crucial in drying conditions. Lowering the drying temperature tends to decrease the t1 / t2 ratio, while raising the drying temperature tends to increase the t1 / t2 ratio. To ensure the thickness of the first resin layer by dissolving a portion of the substrate using the coating liquid for the resin layer and ensuring the flow of the mixture of components dissolved from the substrate and the coating liquid for the resin layer, irradiation with ionizing rays is preferably performed after the coating liquid has dried.

[0304] <Other Layers>

[0305] The anti-glare laminate of the first embodiment and the second embodiment described below, as well as the optical laminate described below, may have layers other than the substrate and the resin layer. Examples of other layers include anti-reflective layers, anti-fouling layers, and antistatic layers.

[0306] <Optical properties, surface shape>

[0307] The total light transmittance of the anti-glare laminate of the first embodiment and the second embodiment described below, as well as the optical laminate described below, according to JIS K7361-1:1997, is preferably 70% or more, more preferably 80% or more, and even more preferably 85% or more.

[0308] The light incident surface when measuring total light transmittance and haze (described later) is the substrate side.

[0309] The haze of the anti-glare laminate of the first embodiment and the second embodiment described below, as well as the optical laminate described below, according to JIS K7136:2000, is preferably 0.5% or more, more preferably 1.0% or more, and even more preferably 1.5% or more. By making the haze 0.5% or more, the anti-glare performance can be easily improved.

[0310] In addition, in order to easily suppress the reduction in image resolution, the haze of the anti-glare laminate of the first embodiment and the second embodiment described later, as well as the optical laminate described later, is preferably 20% or less, more preferably 10% or less, and even more preferably 5% or less.

[0311] Examples of preferred haze ranges for anti-glare laminates and optical laminates include 0.5% to 20%, 0.5% to 10%, 0.5% to 5%, 1.0% to 20%, 1.0% to 10%, 1.0% to 5%, 1.5% to 20%, 1.5% to 10%, and 1.5% to 5%.

[0312] For the anti-glare laminates of the first embodiment and the second embodiment described later, as well as the optical laminate described later, in order to easily improve anti-glare performance, the arithmetic mean roughness Ra of the resin layer side surface according to JIS B0601:2001 is preferably 0.03 μm or more, more preferably 0.05 μm or more. Furthermore, for the anti-glare laminates of the first embodiment and the second embodiment described later, as well as the optical laminate described later, in order to easily suppress the reduction in image resolution, the Ra of the resin layer side surface is preferably 0.12 μm or less, more preferably 0.10 μm or less. Ra refers to the value at a cutoff value of 0.8 mm.

[0313] Examples of preferred ranges for Ra on the surface of the resin layer include 0.03 μm or more and 0.12 μm or less, 0.03 μm or more and 0.10 μm or less, 0.05 μm or more and 0.12 μm or less, and 0.05 μm or more and 0.10 μm or less.

[0314] <Size, shape, etc.>

[0315] The anti-glare laminate of the first embodiment and the second embodiment described later, as well as the optical laminate described later, can be in the form of single sheets cut to a predetermined size, or in the form of long strips rolled into a roll. The size of the single sheet is not particularly limited, but the maximum diameter is approximately 2 inches to 500 inches. "Maximum diameter" refers to the maximum length when any two points of the anti-glare laminate or optical laminate are connected. For example, if the anti-glare laminate or optical laminate is rectangular, the diagonal of the rectangle is the maximum diameter. If the anti-glare laminate or optical laminate is circular, the diameter of the circle is the maximum diameter.

[0316] There are no particular limitations on the width and length of the roll, but it is typically between 500mm and 3000mm in width and between 500m and 5000m in length. Roll-shaped anti-glare laminates or optical laminates can be cut into single sheets according to the size of image display devices, etc. When cutting, it is preferable to remove the ends of the roll that have unstable physical properties.

[0317] The shape of the individual panels is not particularly limited; for example, they can be polygons such as triangles, quadrilaterals, and pentagons, or they can be circles or random amorphous shapes. More specifically, when the anti-glare laminate or optical laminate is quadrilateral, the aspect ratio is not particularly limited as long as it does not pose a problem for the display image. For example, aspect ratios such as horizontal:vertical can be 1:1, 4:3, 16:10, 16:9, 2:1, 5:4, 11:8, etc.

[0318] [Anti-glare laminate according to the second embodiment]

[0319] The anti-glare laminate of the present invention has a resin layer on a substrate.

[0320] The aforementioned resin layer contains a first particle with an average particle size of 0.5 μm or more.

[0321] When the substrate side of the resin layer, extending from its center in the thickness direction, is defined as the first region, and the opposite side of the resin layer, extending from its center in the thickness direction, is defined as the second region, at least 70% of the first particles are present in the second region.

[0322] The anti-glare laminate satisfies either condition 1A or condition 2A.

[0323] <Condition 1A>

[0324] The average tilt angle of the surface of the resin layer side of the above-mentioned substrate is 5.0 degrees or more and 20.0 degrees or less.

[0325] <Condition 2A>

[0326] The arithmetic mean height of the surface of the resin layer side of the above-mentioned substrate is more than 0.10 μm and less than 0.40 μm.

[0327] Figure 5 This is a cross-sectional view showing one embodiment of the anti-glare laminate 100B according to the second embodiment of the present invention.

[0328] Figure 5 The anti-glare laminate 100B has a resin layer 20B on the substrate 10. Additionally, Figure 5 The resin layer 20B contains first particles 23B with an average particle size of 0.5 μm or more. Furthermore, when the side of the resin layer 20B from the center in the thickness direction towards the substrate 10 is defined as a first region 21B, and the opposite side of the resin layer 20B from the center in the thickness direction towards the substrate 10 is defined as a second region 22B, Figure 5 The first particle 23B exists in the second region 22B.

[0329] It should be noted that, Figure 5 This is a schematic cross-sectional view. That is, the scale of each layer, each material, and the surface unevenness of the anti-glare laminate 100B are schematic for ease of illustration and are different from the actual scale. Figure 5 The maps outside of this area also differ from the actual scale.

[0330] <Substrate>

[0331] As a substrate, good light transmittance, smoothness, heat resistance, and mechanical strength are preferred. Examples of such substrates include resin substrates containing resins such as polyester, triacetyl cellulose (TAC), cellulose diacetate, cellulose acetate butyrate, polyamide, polyimide, polyethersulfone, polysulfone, polypropylene, polymethylpentene, polyvinyl chloride, polyvinyl acetal, polyetherketone, acrylic resins, polycarbonate, polyurethane, and amorphous olefins (Cyclo-Olefin-Polymer: COP). The resin substrate can be formed by laminating two or more resin substrates together.

[0332] To improve mechanical strength and dimensional stability, it is preferable to perform a stretching treatment on the resin substrate.

[0333] Among resin substrates, acrylic resin substrates are preferred because they readily improve dimensional stability due to low hygroscopicity and readily improve visibility due to low optical anisotropy. Furthermore, by using a coating liquid with a specified composition for the resin layer and setting specified drying conditions, acrylic resin substrates can easily satisfy conditions 1A and / or 2A and satisfy the position of the first particle in the thickness direction.

[0334] Acrylic resin substrates are hard and brittle, so if a cured resin layer containing a curable resin composition is formed on an acrylic resin substrate, the flexural strength sometimes becomes insufficient. The anti-glare laminate of the present invention, even when a cured resin layer containing a curable resin composition is formed on an acrylic resin substrate, can easily suppress the decrease in flexural strength and maintain pencil hardness by satisfying condition 1A or condition 2A.

[0335] Unless otherwise specified, the embodiment of the acrylic resin substrate in the second embodiment can be the same as the embodiment of the acrylic resin substrate in the first embodiment. For example, the embodiment of the glass transition temperature of the acrylic resin substrate in the second embodiment can be the same as the embodiment of the glass transition temperature of the acrylic resin substrate in the first embodiment.

[0336] The average thickness of the substrate is preferably 10 μm or more, more preferably 20 μm or more, and even more preferably 35 μm or more. By making the average thickness of the substrate 10 μm or more, the operability of the anti-glare laminate can be easily improved.

[0337] The average thickness of the substrate is preferably 100 μm or less, more preferably 80 μm or less, and even more preferably 60 μm or less. By making the average thickness of the substrate 100 μm or less, the bending resistance of the anti-glare laminate can be easily improved.

[0338] Examples of preferred ranges for the average thickness of the substrate include 10 μm to 100 μm, 10 μm to 80 μm, 10 μm to 60 μm, 20 μm to 100 μm, 20 μm to 80 μm, 20 μm to 60 μm, 35 μm to 100 μm, 35 μm to 80 μm, and 35 μm to 60 μm.

[0339] The average thickness of the substrate mentioned above refers to the average thickness of the substrate when the anti-glare laminate is completed. As described later, by dissolving a portion of the substrate using the coating liquid for the resin layer, the average thickness of the substrate when the anti-glare laminate is completed may sometimes be less than the initial average thickness of the substrate. Therefore, the initial average thickness of the substrate is preferably thicker than the average thickness of the substrate when the anti-glare laminate is completed. The difference between the initial average thickness of the substrate and the average thickness of the substrate when the anti-glare laminate is completed varies depending on the thickness of the resin layer, the composition of the coating liquid for the resin layer, the drying conditions of the coating liquid, etc., and therefore cannot be generalized. Preferably, it is 0.1 μm to 10 μm, more preferably 1 μm to 5 μm.

[0340] The average thickness of the substrate can be calculated, for example, by selecting 20 points at any location in a cross-sectional photograph of the anti-glare laminate taken using a scanning transmission electron microscope (STEM) and calculating the average value. The accelerating voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification of the STEM is preferably 1000x or more and 7000x or less.

[0341] To determine the average thickness of the substrate, the thickness of the resin layer, the position of the first particle in the thickness direction of the resin layer, the average tilt angle of the resin layer side surface of the substrate, and the arithmetic mean height of the resin layer side surface of the substrate, it is necessary to prepare a sample for measuring the cross-sectional exposure of the anti-glare laminate. This sample can be prepared, for example, by the steps (A1') to (A2') described below. It should be noted that, in cases where the interface is difficult to see due to insufficient contrast, the sample can be pretreated with osmium tetroxide, ruthenium tetroxide, phosphotungstic acid, etc.

[0342] (A1') Step A1' is the same as step A1 in the first embodiment.

[0343] (A2') The block-shaped embedded sample is vertically cut to create a sample for measurement with the cross-section of the anti-glare laminate exposed. A thin slice cut from the block-shaped embedded sample is used as the sample for measurement (the conditions for the sample measurement are described below). The embedded sample is preferably cut through the center of the sample. The embedded sample is preferably cut with a diamond scalpel.

[0344] As an apparatus for cutting embedded samples, an example is the "Ultra Microtome EMUC7" manufactured by Leica Microsystems. When cutting embedded samples, it is preferable to initially make a rough cut (coarse trimming) and then make a precise trimming at the conditions of "speed: 1.00 mm / s" and "feed: 70 nm".

[0345] As described above, uniform slices cut from block-shaped embedded samples that are free of defects such as pores and have a thickness of 60 nm to 100 nm can be used as samples for measuring the average thickness of the substrate, the thickness of the resin layer, the position of the first particle in the thickness direction of the resin layer, the average tilt angle of the surface of the resin layer side of the substrate, the arithmetic mean height of the surface of the resin layer side of the substrate, the particle size of the first particle, and the particle size of inorganic particles.

[0346] Condition 1A, Condition 2A

[0347] The anti-glare laminate of the second embodiment of the present invention needs to satisfy either condition 1A or condition 2A below. The anti-glare laminate of the second embodiment of the present invention only needs to satisfy at least one of condition 1A and condition 2A, preferably both.

[0348] <Condition 1A>

[0349] The average tilt angle of the surface of the resin layer side of the above-mentioned substrate is 5.0 degrees or more and 20.0 degrees or less.

[0350] <Condition 2A>

[0351] The arithmetic mean height of the surface of the resin layer side of the above-mentioned substrate is more than 0.10 μm and less than 0.40 μm.

[0352] -Condition 1A-

[0353] When the average tilt angle of the substrate is less than 5.0 degrees, the adhesion between the substrate and the resin layer is insufficient, resulting in interfacial peeling when the anti-glare laminate is bent, thus making it difficult to improve the bending resistance of the anti-glare laminate.

[0354] If the average tilt angle of the substrate exceeds 20.0 degrees, it means that the substrate components are excessively dissolved into the resin layer. Therefore, if the average tilt angle of the substrate exceeds 20.0 degrees, it is difficult to improve the pencil hardness of the anti-glare laminate. In addition, if the average tilt angle of the substrate exceeds 20.0 degrees, the internal haze increases, which easily leads to a decrease in resolution.

[0355] The average tilt angle of the substrate is preferably 6.0 degrees or more, more preferably 8.0 degrees or more, and even more preferably 10.0 degrees or more. The average tilt angle of the substrate is preferably 19.5 degrees or less, more preferably 19.0 degrees or less, and even more preferably 18.5 degrees or less.

[0356] Examples of preferred ranges for the average tilt angle of the substrate include 5.0 degrees to 20.0 degrees, 5.0 degrees to 19.5 degrees, 5.0 degrees to 19.0 degrees, 5.0 degrees to 18.5 degrees, 6.0 degrees to 20.0 degrees, 6.0 degrees to 19.5 degrees, 6.0 degrees to 19.0 degrees, 6.0 degrees to 18.5 degrees, 8.0 degrees to 20.0 degrees, 8.0 degrees to 19.5 degrees, 8.0 degrees to 19.0 degrees, 8.0 degrees to 18.5 degrees, 10.0 degrees to 20.0 degrees, 10.0 degrees to 19.5 degrees, 10.0 degrees to 19.0 degrees, and 10.0 degrees to 18.5 degrees.

[0357] The average tilt angle and the arithmetic mean height of the substrate can be determined, for example, by the same method as in the first embodiment.

[0358] -Condition 2A-

[0359] When the arithmetic mean height of the substrate is less than 0.10 μm, the adhesion between the substrate and the resin layer is insufficient, resulting in interfacial peeling when the anti-glare laminate is bent, thus making it difficult to improve the bending resistance of the anti-glare laminate.

[0360] If the arithmetic mean height of the substrate exceeds 0.40 μm, it indicates that substrate components are excessively leaching into the resin layer. Therefore, if the arithmetic mean height of the substrate exceeds 0.40 μm, it is difficult to improve the pencil hardness of the anti-glare laminate. Furthermore, if the arithmetic mean height of the substrate exceeds 0.40 μm, internal haze increases, which easily leads to a decrease in resolution.

[0361] The arithmetic mean height of the substrate is preferably 0.15 μm or more, more preferably 0.20 μm or more. The arithmetic mean height of the substrate is more preferably 0.38 μm or less, and even more preferably 0.36 μm or less.

[0362] Examples of preferred ranges for the arithmetic mean height of the substrate include 0.10 μm to 0.40 μm, 0.10 μm to 0.38 μm, 0.10 μm to 0.36 μm, 0.15 μm to 0.40 μm, 0.15 μm to 0.38 μm, 0.15 μm to 0.36 μm, 0.20 μm to 0.40 μm, 0.20 μm to 0.38 μm, and 0.20 μm to 0.36 μm.

[0363] To ensure that the average tilt angle and arithmetic mean height of the resin layer side surface of the substrate are within the aforementioned range, it is preferable to dissolve a portion of the substrate with a resin layer coating solution. However, when dissolving the substrate with a resin layer coating solution, it is preferable to use a resin layer coating solution with a specified composition and to set specified drying conditions. The specified composition and specified drying conditions are described below.

[0364] <Resin Layer>

[0365] The resin layer needs to contain a first particle with an average particle size of 0.5 μm or more.

[0366] Anti-glare properties cannot be imparted to anti-glare laminates if the resin layer does not contain the first particle.

[0367] For the anti-glare laminate of the present invention, when the substrate side of the resin layer from the center in the thickness direction is defined as the first region and the opposite side of the resin layer from the center in the thickness direction is defined as the second region, it is required that more than 70% of the number of the first particles are present in the second region.

[0368] Reference Figure 5 and Figure 6 , Figure 5 The first particle 23B exists in region 22B. Figure 6 The first particle 23B exists in the first region 21B.

[0369] In the second embodiment, the resin layer is preferably a single layer.

[0370] The statement that more than 70% of the number of particles in the first region does not exist in the second region means that more than 30% of the number of particles in the first region exists in the first region.

[0371] The first particle present in the first region is difficult to make the surface of the resin layer uneven, and therefore it is difficult to improve the anti-glare performance as in Comparative Example 2-2 described later.

[0372] As in Comparative Example 2-1 described later, if the absolute value of the content of the first particle is high, the anti-glare performance can be improved even if more than 70% of the number of the first particles are not present in the second region. However, in this case, the interface between the first particle and the resin layer increases, which is the cause of the reduced flexural strength, and therefore the flexural strength of the anti-glare laminate cannot be improved.

[0373] The proportion of the first particle present in the second region is preferably 75% or more, more preferably 80% or more, based on the number of particles.

[0374] In this specification, the location of the first particle in the thickness direction of the resin layer is determined by the methods described in (1) to (5) below.

[0375] (1) Take cross-sectional photographs of the anti-glare laminate using a scanning transmission electron microscope (STEM). The accelerating voltage of the STEM is preferably above 10kV and below 30kV, and the magnification of the STEM is preferably above 1000x and below 7000x.

[0376] (2) Based on the cross-sectional photographs, calculate the average elevation X1 of the edge lines on the substrate side of the resin layer and the average elevation X2 of the edge lines on the opposite side of the resin layer (refer to...). Figure 5 (The symbols X1 and X2).

[0377] (3) Define the midpoint between the elevations of X1 and X2 as the center M in the thickness direction of the resin layer (refer to...). Figure 5 The symbol M).

[0378] (4) Based on the cross-sectional photographs, the number of first particles existing in the first region on the substrate side of the resin layer from the center in the thickness direction, and the number of first particles existing in the second region on the opposite side of the substrate from the center in the thickness direction of the resin layer are counted. The number of first particles existing in both the first and second regions across the center in the thickness direction of the resin layer is allocated to each region according to the area ratio of each region. For example, the number of first particles that account for 40% of the area of ​​the first region and 60% of the area of ​​the second region is allocated to 0.4 for the first region and 0.6 for the second region.

[0379] (5) In order to improve the reliability of the numerical values, multiple cross-sectional photographs were obtained. After setting the total number of the first particles to 50 or more, the ratio of the number of the first particles in the first region and the second region was calculated.

[0380] A resin layer can be formed, for example, by coating a resin layer coating solution containing a first particle, a resin component, and a solvent onto a substrate, drying it, and then curing it as needed. The resin layer coating solution may also contain inorganic particles and additives as needed.

[0381] In the above method, a portion of the substrate is dissolved in the coating liquid, thereby creating an uneven surface on the resin layer side of the substrate. Components dissolved from the substrate mix with the coating liquid to form the constituent components of the resin layer.

[0382] In the above method, it is important that the resin layer is coated with a specific composition and that the drying conditions are specified. The specified composition and drying conditions are described below.

[0383] There are no particular limitations on the method of applying a resin layer to a substrate using a coating liquid. Common coating methods include spin coating, dip coating, spray coating, mold coating, bar coating, gravure coating, roller coating, meniscus coating, flexographic printing, screen printing, and droplet coating.

[0384] When curing the resin layer with a coating liquid, it is preferable to irradiate it with ionizing rays such as ultraviolet light and electron beams. Specific examples of ultraviolet light sources include ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black fluorescent lamps, and metal halide lamps. Furthermore, the wavelength of the ultraviolet light is preferably in the wavelength range of 190 nm to 380 nm. Specific examples of electron beam sources include various electron beam accelerators such as Cockcroft-Walton type, van der Graff type, resonant transformer type, insulated core transformer type, linear type, Dynamitron type, and high-frequency type.

[0385] The lower limit of the average thickness of the resin layer is preferably 6.0 μm or more, more preferably 7.0 μm or more, and even more preferably 8.0 μm or more, and the upper limit is preferably 15.0 μm or less, more preferably 14.0 μm or less, and even more preferably 13.0 μm or less.

[0386] By making the average thickness of the resin layer 6.0 μm or more, the hardness of the pencil can be easily improved. By making the average thickness of the resin layer 15.0 μm or less, the reduction in flexural strength can be easily suppressed.

[0387] Examples of preferred ranges for the average thickness of the resin layer include 6.0 μm to 15.0 μm, 6.0 μm to 14.0 μm, 6.0 μm to 13.0 μm, 7.0 μm to 15.0 μm, 7.0 μm to 14.0 μm, 7.0 μm to 13.0 μm, 8.0 μm to 15.0 μm, 8.0 μm to 14.0 μm, and 8.0 μm to 13.0 μm.

[0388] The average thickness of the resin layer can be calculated, for example, by selecting 20 points at any location in a cross-sectional photograph of the anti-glare laminate taken using a scanning transmission electron microscope (STEM) and calculating the average value. The accelerating voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification of the STEM is preferably 1000x or more and 7000x or less.

[0389] The First Particle

[0390] The first particle consists of particles with an average particle size of 0.5 μm or larger. If the average particle size is less than 0.5 μm, it is difficult to form an uneven shape on the surface of the resin layer, thus failing to improve the anti-glare performance.

[0391] Examples of the first particle include organic particles formed from one or more resins selected from polymethyl methacrylate, polyacrylic acid-styrene copolymer, melamine resin, polycarbonate, polystyrene, polyvinyl chloride, benzoguanamine-melamine-formaldehyde condensate, organosilicon, fluorinated resin, and polyester resin; and inorganic particles formed from one or more inorganic substances selected from silica, alumina, zirconium oxide, and titanium dioxide. Organic particles exhibit excellent dispersion stability and a relatively low specific gravity, making them preferred from the perspective of easily satisfying the positional requirements in the thickness direction.

[0392] The lower limit of the content of the first particle is preferably 0.5 parts by mass or more, more preferably 1.0 parts by mass or more, and even more preferably 1.5 parts by mass or more, and the upper limit is preferably 10.0 parts by mass or less, more preferably 5.0 parts by mass or less, and even more preferably 3.0 parts by mass or less, relative to 100 parts by mass of the resin component in the coating liquid for the resin layer.

[0393] By making the content of the first particle 0.5 parts by mass or more, the anti-glare property can be easily improved. In addition, by making the content of the first particle 10.0 parts by mass or less, the reduction in flexural strength can be easily suppressed.

[0394] Examples of preferred ranges for the content of the first particle relative to 100 parts by weight of resin include 0.5 parts by weight to 10.0 parts by weight, 0.5 parts by weight to 5.0 parts by weight, 0.5 parts by weight to 3.0 parts by weight, 1.0 parts by weight to 10.0 parts by weight, 1.0 parts by weight to 5.0 parts by weight, 1.0 parts by weight to 3.0 parts by weight, 1.5 parts by weight to 10.0 parts by weight, 1.5 parts by weight to 5.0 parts by weight, and 1.5 parts by weight to 3.0 parts by weight.

[0395] The average particle size of the first particle is preferably 0.8 μm or more, more preferably 1.0 μm or more.

[0396] In order to make it easy for the first particle to meet the positional conditions in the thickness direction, the average particle size of the first particle is preferably 3.0 μm or less, more preferably 2.7 μm or less, and even more preferably 2.5 μm or less.

[0397] Examples of preferred ranges for the average particle size of the first particle include 0.8 μm to 3.0 μm, 0.8 μm to 2.7 μm, 0.8 μm to 2.5 μm, 1.0 μm to 3.0 μm, 1.0 μm to 2.7 μm, and 1.0 μm to 2.5 μm.

[0398] The average particle size of the first particle can be calculated, for example, using the same method as in the first embodiment.

[0399] The relationship between D1, which represents the average particle size of the first particle, and t, which represents the average thickness of the resin layer, is preferably 2.0 < t / D1 < 6.0.

[0400] By making t / D1 less than 6.0, the surface of the anti-glare laminate can be easily given an uneven shape using the first particle, thus easily improving the anti-glare performance. By making t / D1 greater than 2.0, it is easy to suppress the reduction in flexural strength caused by the first particle protruding from the surface of the resin layer.

[0401] The lower limit of t / D1 is more preferably 2.5 or more, further preferably 3.5 or more, and the upper limit is more preferably 5.0 or less, further preferably 4.5 or less.

[0402] Examples of preferred ranges for t / D1 include values ​​greater than 2.0 and less than 6.0, greater than 2.0 and less than 5.0, greater than 2.0 and less than 4.5, greater than 2.5 and less than 6.0, greater than 2.5 and less than 5.0, greater than 2.5 and less than 4.5, greater than 3.5 and less than 6.0, greater than 3.5 and less than 5.0, and greater than 3.5 and less than 4.5.

[0403] In order to easily suppress the decrease in bending resistance, the lower limit of t-D1 is preferably 2.0 μm or more, more preferably 3.0 μm or more, and even more preferably 4.0 μm or more. In order to easily improve anti-glare performance, the upper limit is preferably 10 μm or less, more preferably 8.0 μm or less, and even more preferably 7.0 μm or less.

[0404] Examples of preferred ranges for t-D1 include 2.0 μm to 10 μm, 2.0 μm to 8.0 μm, 2.0 μm to 7.0 μm, 3.0 μm to 10 μm, 3.0 μm to 8.0 μm, 3.0 μm to 7.0 μm, 4.0 μm to 10 μm, 4.0 μm to 8.0 μm, and 4.0 μm to 7.0 μm.

[0405] Inorganic Particles

[0406] The resin layer can contain inorganic microparticles. By including relatively heavy inorganic microparticles in the resin layer, the first particle is less likely to sink to the bottom of the resin layer, thus easily satisfying the positional requirements in the thickness direction. Furthermore, the inorganic microparticles improve the dispersibility of the first particle, effectively suppressing any decrease in flexural strength.

[0407] The implementation of the average particle size and type of inorganic particles in the second embodiment can be the same as the implementation of the average particle size and type of inorganic particles in the first embodiment.

[0408] The content of inorganic microparticles is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, and even more preferably 0.7 parts by mass or more, and the upper limit is preferably 5.0 parts by mass or less, more preferably 3.0 parts by mass or less, and even more preferably 2.0 parts by mass or less, relative to 100 parts by mass of the resin component in the coating liquid for the resin layer.

[0409] By making the content of inorganic microparticles 0.1 parts by mass or more, the first particle can easily meet the positional requirements in the thickness direction. In addition, by making the content of inorganic microparticles 5.0 parts by mass or less, the first particle can be prevented from excessively floating on the resin layer, thus easily suppressing the reduction of flexural strength.

[0410] Examples of preferred ranges for the content of inorganic particles relative to 100 parts by weight of resin include 0.1 to 5.0 parts by weight, 0.1 to 3.0 parts by weight, 0.1 to 2.0 parts by weight, 0.5 to 5.0 parts by weight, 0.5 to 3.0 parts by weight, 0.5 to 2.0 parts by weight, 0.7 to 5.0 parts by weight, 0.7 to 3.0 parts by weight, and 0.7 to 2.0 parts by weight.

[0411] Resin Composition

[0412] The resin layer preferably contains a cured product of a curable resin composition as the resin component. By including a cured product of a curable resin composition in the resin layer, the pencil hardness of the anti-glare laminate can be easily improved.

[0413] The ratio of the curable resin composition to the total amount of resin component in the coating liquid for the resin layer is preferably 80% by mass or more, more preferably 90% by mass or more, further preferably 95% by mass or more, and most preferably 100% by mass.

[0414] Examples of cured products of curable resin compositions include cured products of thermosetting resin compositions and cured products of ionizing radiation-curable resin compositions. Among these, cured products of ionizing radiation-curable resin compositions that readily increase pencil hardness and readily dissolve the substrate in the uncured state are preferred.

[0415] The second embodiment of the thermosetting resin composition can be the same as the embodiment of the first embodiment of the thermosetting resin composition.

[0416] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). Examples of ionizing radiation-curable functional groups include olefinic unsaturated groups such as (meth)acryloyl, vinyl, and allyl, as well as epoxy and oxetyl groups. Compounds having olefinic unsaturated groups are preferred as ionizing radiation-curable compounds.

[0417] Ionizing rays are electromagnetic waves or charged particle beams that contain energy quanta capable of polymerizing or cross-linking molecules. They are usually ultraviolet rays or electron rays. In addition, electromagnetic waves such as X-rays and gamma rays, as well as charged particle beams such as alpha rays and ion beams can also be used.

[0418] In this specification, (meth)acryloyl group means acryloyl group or methacryloyl group. Additionally, in this specification, (meth)acrylate means acrylate or methacrylate.

[0419] As an ionizing ray curable compound, either a monofunctional ionizing ray curable compound having one ionizing ray curable functional group or a polyfunctional ionizing ray curable compound having two or more ionizing ray curable functional groups can be used. Furthermore, either a monomer or an oligomer can be used as an ionizing ray curable compound.

[0420] To dissolve a portion of the substrate, increase pencil hardness, and easily suppress curing shrinkage, the mixture of (a) to (c) below is preferably used as the ionizing radiation curable compound. (a) to (c) below are preferably compounds having olefinic unsaturated bond groups as ionizing radiation curable functional groups, and more preferably (meth)acrylate compounds. (Meth)acrylate compounds can also be compounds obtained by modifying a portion of the molecular skeleton using ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl groups, cyclic alkyl groups, aromatic compounds, bisphenols, etc.

[0421] (a) Monofunctional ionizing radiation-curable monomer

[0422] (b) Multifunctional ionizing radiation-curable monomers

[0423] (c) Multifunctional ionizing radiation-cured oligomers

[0424] By using a monofunctional ionizing radiation-curable monomer containing (a) as an ionizing radiation-curable compound, a portion of the substrate can be easily dissolved, thus easily satisfying condition 1A or condition 2A. Furthermore, by using a monofunctional ionizing radiation-curable monomer containing (a), the components dissolved from the substrate can be easily made compatible with the components of the coating liquid for the resin layer, thus easily improving the physical properties of the resin layer.

[0425] However, if the amount of monofunctional ionizing ray curable monomer in (a) is too large, it will over-dissolve the substrate, thus sometimes reducing the strength of the substrate or the pencil hardness of the anti-glare laminate.

[0426] By using a multifunctional ionizing radiation-curable monomer containing (b) as an ionizing radiation-curable compound, the pencil hardness of the anti-glare laminate can be easily improved. However, if the amount of the multifunctional ionizing radiation-curable monomer (b) is too large, the hardness of the resin layer may become too high, and the bending resistance of the anti-glare laminate may decrease.

[0427] By using a multifunctional ionizing radiation-curable oligomer containing (c) as the ionizing radiation-curable compound, it is possible to easily suppress curing shrinkage while maintaining the pencil hardness of the anti-glare laminate. However, if the amount of the multifunctional ionizing radiation-curable oligomer containing (c) is too large, the pencil hardness of the anti-glare laminate may sometimes decrease.

[0428] Relative to the total amount of the ionizing radiation curable compound, the amount of the monofunctional ionizing radiation curable monomer of (a) is preferably 10% by mass or more and 40% by mass or less, more preferably 13% by mass or more and 30% by mass or less, and even more preferably 15% by mass or more and 25% by mass or less.

[0429] Relative to the total amount of the ionizing radiation curable compound, the amount of the multifunctional ionizing radiation curable monomer in (b) is preferably 5% by mass or more and 20% by mass or less, more preferably 6% by mass or more and 15% by mass or less, and even more preferably 7% by mass or more and 13% by mass or less.

[0430] Relative to the total amount of the ionizing radiation curable compound, (c) the amount of the multifunctional ionizing radiation curable oligomer is preferably 50% by mass or more and 85% by mass or less, more preferably 60% by mass or more and 80% by mass or less, and even more preferably 65% ​​by mass or more and 75% by mass or less.

[0431] The embodiments of the monofunctional ionizing radiation curable monomer (a) of the second embodiment, the multifunctional ionizing radiation curable monomer (b) and the multifunctional ionizing radiation curable oligomer (c) can be the same as the embodiments of the monofunctional ionizing radiation curable monomer (a) of the first embodiment, the multifunctional ionizing radiation curable monomer (b) and the multifunctional ionizing radiation curable oligomer (c).

[0432] When the ionizing ray curable compound is an ultraviolet curable compound, the ionizing ray curable composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator, just like in the first embodiment.

[0433] The coating liquid for the resin layer may contain additives as needed, similar to that in the first embodiment.

[0434] Solvent

[0435] The coating liquid for the resin layer preferably contains a solvent.

[0436] As a solvent, it is preferable to choose one that can dissolve the substrate. However, if the substrate is over-dissolved, the strength of the substrate will decrease; therefore, it is preferable to select an appropriate solvent based on the type of substrate. Preferably, the solvent contains three components with a polar component δp of 7.0 (J / cm³) based on the Hansen solubility parameter. 3 ) 0.5 The above 10.0 (J / cm) 3 ) 0.5 The following solvents. By making δp 7.0 (J / cm) 3 ) 0.5 The above allows the substrate to be easily dissolved by setting δp to 10.0 (J / cm). 3 ) 0.5 The following methods can avoid excessive dissolution. δp[(J / cm] for toluene, isopropanol (IPA), methyl ethyl ketone (MEK), and methyl isobutyl ketone (MIBK) 3 ) 0.5 The value of ] is as follows.

[0437] ([Toluene: 1.4, IPA: 6.1, MEK: 9.0, MIBK: 6.1])

[0438] Furthermore, solvent selection considers not only the solubility in the substrate but also the inherent evaporation rate of the solvent. This is because a slow solvent evaporation rate can easily lead to over-dissolving of the substrate. The solvent evaporation rate can also be controlled by the drying conditions. For example, increasing the drying temperature accelerates the solvent evaporation rate. Additionally, increasing the drying air velocity also accelerates the solvent evaporation rate.

[0439] Therefore, solvents should be selected with consideration of the solubility of the substrate, evaporation rate, and drying conditions.

[0440] The second embodiment may be the same as the first embodiment in terms of the type of solvent.

[0441] Acrylic resin substrates are readily soluble in solvents. Therefore, when using acrylic resin substrates, it is preferable to use a solvent with a fast evaporation rate as the main component. The main component refers to 50% by mass or more of the total solvent, preferably 70% by mass or more, more preferably 90% by mass or more, and most preferably 100% by mass.

[0442] In this specification, a solvent with a fast evaporation rate refers to a solvent with an evaporation rate of 100 or higher when the evaporation rate of butyl acetate is set to 100. More preferably, the evaporation rate of a solvent with a fast evaporation rate is 120 to 450, and even more preferably 140 to 400.

[0443] Examples of solvents with fast evaporation rates include isopropanol (evaporation rate 150), methyl isobutyl ketone (evaporation rate 160), toluene (evaporation rate 200), and methyl ethyl ketone (evaporation rate 370).

[0444] Furthermore, the solvent preferably contains a solvent with a small molecular weight and high polarity. The highly polar solvent is preferably one whose Hansen solubility parameter δp is within the aforementioned range. By using a solvent containing a small molecular weight, high polarity, and the aforementioned evaporation rate, acrylic resin substrates can be easily and appropriately dissolved. Methyl ethyl ketone is an example of such a solvent.

[0445] To easily satisfy condition 1A or condition 2A, the amount of methyl ethyl ketone is preferably 20% to 40% by mass of the total amount of solvent.

[0446] Drying conditions

[0447] When forming a resin layer from a resin layer using a coating liquid, it is preferable to control the drying conditions.

[0448] Furthermore, the anti-glare laminate of the present invention preferably undergoes two stages of drying of the coating liquid for the resin layer. Specifically, it is preferable that the drying intensity is reduced in the first stage and increased in the second stage. During the weak drying in the first stage, the substrate dissolves, forming a mixture of components dissolved from the substrate and components of the coating liquid for the resin layer. This extends the convection time of the mixture, thus easily satisfying the positional requirements of the first particle in the thickness direction. Additionally, by reducing the drying intensity in the first stage, the components dissolved from the substrate and components of the coating liquid for the resin layer mix more easily, making it easier to form a single resin layer. Furthermore, by performing strong drying in the second stage, excessive dissolution of the substrate can be suppressed, thus easily preventing the average tilt angle and arithmetic mean height of the substrate from becoming excessively large.

[0449] Drying conditions can be controlled by the drying temperature and the air velocity within the dryer. The preferred ranges for drying temperature and air velocity vary depending on the composition of the coating liquid used for the resin layer, and therefore cannot be generalized. The following conditions are preferred.

[0450] <Stage 1 Drying>

[0451] The preferred drying temperature is 65℃ to 85℃, and the preferred drying air velocity is 0.5m / s to 2m / s. The preferred drying time is 20 seconds to 40 seconds.

[0452] <Stage 2 Drying>

[0453] The preferred drying temperature is 65℃ to 85℃, and the preferred drying air velocity is 15m / s to 25m / s. The preferred drying time is 20 seconds to 40 seconds.

[0454] In order to dissolve a portion of the substrate using the coating liquid for the resin layer and to facilitate thorough mixing of the components dissolved from the substrate with the coating liquid for the resin layer, irradiation with ionizing rays is preferably performed after the coating liquid has dried.

[0455] [Optical laminates]

[0456] The optical laminate of the present invention has a resin layer on a substrate.

[0457] The resin layer described above has a first resin layer and a second resin layer from the substrate side.

[0458] The first resin layer described above has mutually independent regions α1 and regions α2 surrounding regions α1. The resin contained in regions α1 is different from the resin contained in regions α2.

[0459] The second resin layer described above has a mutually independent region β1 and a region β2 surrounding the region β1. The resin contained in the region β1 is different from the resin contained in the region β2.

[0460] The optical laminate satisfies either condition 1B or condition 2B.

[0461] <Condition 1B>

[0462] The average tilt angle θa1 of the surface representing the resin layer side of the substrate and the average tilt angle θa2 of the surface representing the second resin layer side of the first resin layer satisfy the relationship θa2<θa1.

[0463] <Condition 2B>

[0464] Pa1, which represents the arithmetic mean height of the surface of the resin layer side of the substrate, and Pa2, which represents the arithmetic mean height of the surface of the second resin layer side of the first resin layer, satisfy the relationship Pa2 < Pa1.

[0465] Figure 8 This is a cross-sectional view illustrating one embodiment of the optical laminate 100C of the present invention.

[0466] Figure 8The optical laminate 100C has a resin layer 20C on the substrate 10. Additionally, Figure 8 The resin layer 20C has a first resin layer 21C and a second resin layer 22C from the substrate 10 side.

[0467] in addition, Figure 8 The first resin layer 21C has mutually independent regions α1 and regions α2 surrounding the aforementioned regions α1. Furthermore, Figure 8 The second resin layer 22C has mutually independent regions β1 and regions β2 surrounding the aforementioned regions β1. In this specification, it is sometimes referred to as... Figure 8 The structure that has an independent region n1 and a region n2 surrounding the first resin layer and the second resin layer is called an "island structure".

[0468] It should be noted that, Figure 8 It is a schematic cross-sectional view. That is, the scale of each layer, each material, and the surface unevenness of the optical laminate 100C are schematic for ease of illustration and are different from the actual scale. Figure 8 The maps outside of this area also differ from the actual scale.

[0469] <Substrate>

[0470] As a substrate, good light transmittance, smoothness, heat resistance, and mechanical strength are preferred. Examples of such substrates include resin substrates containing resins such as polyester, triacetyl cellulose (TAC), cellulose diacetate, cellulose acetate butyrate, polyamide, polyimide, polyethersulfone, polysulfone, polypropylene, polymethylpentene, polyvinyl chloride, polyvinyl acetal, polyetherketone, acrylic resins, polycarbonate, polyurethane, and amorphous olefins (Cyclo-Olefin-Polymer: COP). The resin substrate can be formed by laminating two or more resin substrates together.

[0471] To improve mechanical strength and dimensional stability, it is preferable to perform a stretching treatment on the resin substrate.

[0472] Among resin substrates, acrylic resin substrates are preferred because their low hygroscopicity readily improves dimensional stability and their low optical anisotropy readily improves visibility. Furthermore, by using a coating liquid with a specified composition and setting specified drying conditions, acrylic resin substrates can satisfy conditions 1B and / or 2B and easily form the first and second resin layers into an island structure.

[0473] Acrylic resin substrates are hard and brittle, making it difficult to improve adhesion when other layers are formed on them. In particular, when a hard resin layer, such as a cured resin layer containing a curable resin composition, is formed on an acrylic resin substrate, the adhesion between the substrate and the resin layer tends to become insufficient. The optical laminate of the present invention, even when a cured resin layer containing a curable resin composition is formed on an acrylic resin substrate, can suppress the decrease in adhesion and easily suppress changes in image sharpness by satisfying condition 1B or condition 2B and having the resin layer with an island structure, etc.

[0474] In this specification, acrylic resins refer to acrylic resins and / or methacrylic resins.

[0475] Unless otherwise specified, the embodiment of the acrylic resin substrate of the optical laminate can be the same as the embodiment of the acrylic resin substrate of the first embodiment. For example, the embodiment of the glass transition temperature of the acrylic resin substrate of the optical laminate can be the same as the embodiment of the glass transition temperature of the acrylic resin substrate of the first embodiment.

[0476] The weight-average molecular weight of the resin, such as acrylic resin, included in the resin matrix is ​​preferably 10,000 to 500,000, more preferably 50,000 to 300,000. By making the weight-average molecular weight of the resin within the above range, conditions 1B and 2B, and the aforementioned island structure, can be easily controlled.

[0477] The average thickness of the substrate is preferably 10 μm or more, more preferably 20 μm or more, and even more preferably 35 μm or more. By making the average thickness of the substrate 10 μm or more, the operability of the optical laminate can be easily improved.

[0478] The average thickness of the substrate is preferably 100 μm or less, more preferably 80 μm or less, and even more preferably 60 μm or less. By making the average thickness of the substrate 100 μm or less, the bending resistance of the optical laminate can be easily improved.

[0479] Examples of preferred ranges for the average thickness of the substrate include 10 μm to 100 μm, 10 μm to 80 μm, 10 μm to 60 μm, 20 μm to 100 μm, 20 μm to 80 μm, 20 μm to 60 μm, 35 μm to 100 μm, 35 μm to 80 μm, and 35 μm to 60 μm.

[0480] The average thickness of the substrate mentioned above refers to the average thickness of the substrate when the optical laminate is completed. As described later, by dissolving a portion of the substrate using the coating liquid for the resin layer, the average thickness of the substrate when the optical laminate is completed may sometimes be less than the initial average thickness of the substrate. Therefore, the initial average thickness of the substrate is preferably thicker than the average thickness of the substrate when the optical laminate is completed. The difference between the initial average thickness of the substrate and the average thickness of the substrate when the optical laminate is completed varies depending on the thickness of the resin layer, the composition of the coating liquid for the resin layer, the drying conditions of the coating liquid, etc., and therefore cannot be generalized. Preferably, it is 0.1 μm to 10 μm, more preferably 1 μm to 5 μm.

[0481] The average thickness of the substrate can be calculated, for example, by selecting 20 points at any location in a cross-sectional photograph of the optical laminate taken using a scanning transmission electron microscope (STEM) and calculating the average value. The accelerating voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification of the STEM is preferably 1000x or more and 7000x or less.

[0482] To determine the average thickness of the substrate, the thickness of the first resin layer, the thickness of the second resin layer, the position of region α1 in the thickness direction of the first resin layer, the position of the first particle in the thickness direction of the resin layer, θa1, θa2, Pa1, Pa2, etc., it is necessary to prepare a sample for measuring the cross-sectional exposure of the optical laminate. This sample can be prepared, for example, by the steps (A1”) to (A2”) described below. It should be noted that, in cases where the interface is difficult to see due to insufficient contrast, the sample can be pretreated with osmium tetroxide, ruthenium tetroxide, phosphotungstic acid, etc.

[0483] (A1”) Process A1” is the same as process A1 in the first embodiment.

[0484] (A2”) The block-shaped embedded sample is vertically cut to create a sample for measurement with the cross-section of the optical laminate exposed. A thin slice cut from the block-shaped embedded sample is used as the measurement sample (conditions for the measurement sample are described below). The embedded sample is preferably cut through the center of the sample. The embedded sample is preferably cut with a diamond cutter.

[0485] As an apparatus for cutting embedded samples, an example is the "Ultra Microtome EMUC7" manufactured by Leica Microsystems. When cutting embedded samples, it is preferable to initially make a rough cut (coarse trimming) and then make a precise trimming at the conditions of "speed: 1.00 mm / s" and "feed: 70 nm".

[0486] As described above, uniform slices cut from block-shaped embedded samples that are free of defects such as pores and have a thickness of 60 nm to 100 nm can be used as samples for measuring the average thickness of the substrate, the thickness of the first resin layer, the thickness of the second resin layer, the position of region α1 in the thickness direction of the first resin layer, the position of the first particle in the thickness direction of the resin layer, θa1, θa2, Pa1, Pa2, the particle size of the first particle, and the particle size of inorganic particles.

[0487] <Resin Layer>

[0488] The resin layer needs to have a first resin layer and a second resin layer starting from the substrate side. By having a first resin layer and a second resin layer as the resin layer, the adhesion can be improved, and the reduction of pencil hardness can be easily suppressed.

[0489] When the resin layer is a single layer, it is difficult to improve the flexural strength or pencil hardness of the optical laminate. For example, it is difficult to improve the flexural strength of the optical laminate when the resin layer has high hardness. Conversely, it is difficult to improve the pencil hardness of the optical laminate when the resin layer has low hardness.

[0490] The first and second resin layers can be formed, for example, by coating a resin layer coating liquid containing components that become resin and a solvent onto a substrate and drying it, followed by curing as needed. The resin layer coating liquid may also contain first particles, inorganic particles, and additives, as needed.

[0491] In the above method, for example, by dissolving a portion of the substrate with the resin coating liquid, a first resin layer can be formed from a region where the resin component dissolved from the substrate is the main component and a small amount of resin component from the resin coating liquid is included. Then, a second resin layer can be formed from a region where the content of the resin component dissolved from the substrate is low and the resin component from the resin coating liquid is the main component. That is, in the above method, both the first and second resin layers can be formed by a single coating with one type of resin coating liquid. Furthermore, the second resin layer formed by the above method has a low content of resin component dissolved from the substrate, thus easily improving pencil hardness.

[0492] In the above method, it is important that the resin layer is coated with a specific composition and that the drying conditions are specified. The specified composition and drying conditions are described below.

[0493] There are no particular limitations on the method of applying a resin layer to a substrate using a coating liquid. Common coating methods include spin coating, dip coating, spray coating, mold coating, bar coating, gravure coating, roller coating, meniscus coating, flexographic printing, screen printing, and droplet coating.

[0494] When curing the resin layer with a coating liquid, it is preferable to irradiate it with ionizing rays such as ultraviolet light and electron beams. Specific examples of ultraviolet light sources include ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black fluorescent lamps, and metal halide lamps. Furthermore, the wavelength of the ultraviolet light is preferably in the wavelength range of 190 nm to 380 nm. Specific examples of electron beam sources include various electron beam accelerators such as Cockcroft-Walton type, van der Graff type, resonant transformer type, insulated core transformer type, linear type, Dynamitron type, and high-frequency type.

[0495] The first resin layer needs to have a mutually independent region α1 and a region α2 surrounding the region α1, wherein the resin contained in region α1 is different from the resin contained in region α2. Similarly, the second resin layer needs to have a mutually independent region β1 and a region β2 surrounding the region β1, wherein the resin contained in region β1 is different from the resin contained in region β2.

[0496] By having the first resin layer have the aforementioned regions α1 and α2, and the second resin layer have the aforementioned regions β1 and β2, the adhesion after the lightfastness test can be easily improved.

[0497] The resin contained in region α1 differs from that contained in region α2 in that at least one of the resin composition and molecular weight is different. Preferably, the resin contained in region α1 and the resin contained in region α2 have different resin compositions. Examples of different resin compositions include cases where region α1 and region α2 contain different types of resin, or cases where region α1 and region α2 contain the same type of resin but with different mixing ratios.

[0498] The resin contained in region β1 differs from that contained in region β2 in that at least one of the resin composition and molecular weight is different. Preferably, the resin contained in region β1 and the resin contained in region β2 have different resin compositions. Examples of different resin compositions include cases where region β1 and region β2 contain different types of resin, or cases where region β1 and region β2 contain the same type of resin but with different mixing ratios.

[0499] In this specification, the resins of regions α1, α2, β1, and β2 refer to so-called adhesive resins. Therefore, the particles such as the first particle mentioned later do not necessarily refer to the resins of regions α1, α2, β1, and β2.

[0500] When the proportion of region α1 is high, the hardness is easily insufficient; when the proportion of region α2 is high, the adhesion is easily deteriorated. Therefore, the area ratio of region α1 to region α2 is preferably 1:99 to 10:90, more preferably 2:98 to 5:95.

[0501] When the proportion of region β1 is high, the hardness is easily insufficient; when the proportion of region β2 is high, the adhesion is easily deteriorated. Therefore, the area ratio of region β1 to region β2 is preferably 5:95 to 50:50, more preferably 10:90 to 40:60.

[0502] The area ratios mentioned above can be calculated from cross-sectional photographs of the optical laminates taken using a scanning transmission electron microscope (STEM). To improve the reliability of the values, it is preferable to obtain multiple cross-sectional photographs, set the sum of regions α1 or β1 to 50 or more, and then calculate the area ratios.

[0503] The resin contained in region α1 of the first resin layer and region β2 is preferably substantially the same as the resin contained in region β2, and preferably the resin contained in region α2 is substantially the same as the resin contained in region β1. With this configuration, the adhesion after the lightfastness test can be easily improved. The reason why the adhesion after the lightfastness test can be easily improved with this configuration is that by increasing the affinity between the first resin layer and the second resin layer, the adhesion of the interface between the first resin layer and the second resin layer is not easily reduced even under harsh environments such as lightfastness tests.

[0504] In order to facilitate the formation of the first resin layer having the aforementioned regions α1 and α2, and in order to facilitate the formation of the second resin layer having the aforementioned regions β1 and β2, it is preferable to reduce the compatibility between the components contained in the coating liquid for the resin layer, or to reduce the compatibility between the components contained in the coating liquid for the resin layer and the components dissolved from the substrate.

[0505] It is believed that by reducing compatibility as described above, and through the phenomena described in (1) to (4) below, the first resin layer and the second resin layer can be easily formed in the optical laminate of the present invention.

[0506] (1) When the coating liquid is used to coat the resin layer on the substrate, a portion of the substrate dissolves.

[0507] (2) The region containing resin components mainly derived from the substrate and a small amount of resin components from the coating liquid for the resin layer is called the first resin layer, and the region containing less resin components derived from the substrate and a small amount of resin components mainly derived from the coating liquid for the resin layer is called the second resin layer.

[0508] (3) Due to low compatibility, in the above (2), the resin component of the coating liquid contained in the first resin layer forms region α1, and the resin component dissolved from the substrate forms region α2.

[0509] (4) Due to low compatibility, in the above (2), the resin component dissolved from the substrate contained in the second resin layer forms region β1, and the resin component of the resin layer forms region β2 with the coating liquid.

[0510] When the substrate side of the first resin layer, extending from its center in the thickness direction, is defined as the first region, and the second resin layer side of the first resin layer, extending from its center in the thickness direction, is defined as the second region, it is preferable that at least 70% of region α1 exists in the second region. With this configuration, the adhesion after the lightfastness test can be easily further improved.

[0511] The proportion of region α1 present in the second region is preferably 80% or more, more preferably 90% or more, and even more preferably 95% or more, based on the number of regions.

[0512] In this specification, the location of region α1 in the thickness direction of the first resin layer is determined by the methods described in (1) to (5) below.

[0513] (1) Take cross-sectional photographs of the optical laminate using a scanning transmission electron microscope (STEM). The accelerating voltage of the STEM is preferably above 10kV and below 30kV, and the magnification of the STEM is preferably above 1000x and below 7000x.

[0514] (2) Based on the cross-sectional photographs, calculate the average elevation X1 of the edge line on the substrate side of the first resin layer and the average elevation X2 of the edge line on the second resin layer side of the first resin layer (refer to...). Figure 9 (The symbols X1 and X2).

[0515] (3) Define the midpoint between the elevations of X1 and X2 as the center M in the thickness direction of the first resin layer (refer to...). Figure 9 The symbol M).

[0516] (4) Based on the cross-sectional photographs, the number of regions α1 existing in the first region on the substrate side from the center of the first resin layer in the thickness direction, and the number of regions α1 existing in the second resin layer side from the center of the first resin layer in the thickness direction are counted. The number of regions α1 existing in both the first and second regions that span the center of the first resin layer in the thickness direction is allocated to the first and second regions according to the area ratio of regions α1. For example, regions α1 that have an area ratio of 40% in the first region and an area ratio of 60% in the second region are allocated 0.4 to the first region and 0.6 to the second region.

[0517] (5) In order to improve the reliability of the numerical values, multiple cross-sectional photographs were obtained. After setting the total number of regions α1 to 50 or more, the ratio of the number of regions α1 existing in the first region and the second region was calculated.

[0518] The lower limit of the overall thickness of the resin layer (in other words, the total thickness of the first resin layer and the second resin layer) is preferably 4.0 μm or more, more preferably 5.0 μm or more, and even more preferably 6.0 μm or more, and the upper limit is preferably 15.0 μm or less, more preferably 12.0 μm or less, and even more preferably 10.0 μm or less.

[0519] Examples of preferred ranges for the overall thickness of the resin layer include 4.0 μm to 15.0 μm, 4.0 μm to 12.0 μm, 4.0 μm to 10.0 μm, 5.0 μm to 15.0 μm, 5.0 μm to 12.0 μm, 5.0 μm to 10.0 μm, 6.0 μm to 15.0 μm, 6.0 μm to 12.0 μm, and 6.0 μm to 10.0 μm.

[0520] The lower limit of the average thickness t1 of the first resin layer is preferably 3.0 μm or more, more preferably 4.0 μm or more, and even more preferably 4.5 μm or more, and the upper limit is preferably 10.0 μm or less, more preferably 8.0 μm or less, and even more preferably 7.0 μm or less. By making t1 3.0 μm or more, the adhesion and bending resistance can be easily improved, and by making t1 10.0 μm or less, the reduction in pencil hardness can be easily suppressed.

[0521] Examples of preferred ranges for t1 include 3.0 μm to 10.0 μm, 3.0 μm to 8.0 μm, 3.0 μm to 7.0 μm, 4.0 μm to 10.0 μm, 4.0 μm to 8.0 μm, 4.0 μm to 7.0 μm, 4.5 μm to 10.0 μm, 4.5 μm to 8.0 μm, and 4.5 μm to 7.0 μm.

[0522] The lower limit of the average thickness t2 of the second resin layer is preferably 0.3 μm or more, more preferably 0.5 μm or more, and even more preferably 1.0 μm or more, and the upper limit is preferably 4.0 μm or less, more preferably 3.0 μm or less, and even more preferably 2.7 μm or less. By making t2 0.3 μm or more, the pencil hardness can be easily improved, and by making t2 4.0 μm or less, the reduction in flexural strength can be easily suppressed.

[0523] Examples of preferred ranges for t2 include 0.3μm to 4.0μm, 0.3μm to 3.0μm, 0.3μm to 2.7μm, 0.5μm to 4.0μm, 0.5μm to 3.0μm, 0.5μm to 2.7μm, 1.0μm to 4.0μm, 1.0μm to 3.0μm, and 1.0μm to 2.7μm.

[0524] To easily suppress the decrease in sealing and bending resistance, t1 / t2 is preferably 1.5 or more, more preferably 1.8 or more, and even more preferably 2.0 or more. Furthermore, to easily improve pencil hardness, t1 / t2 is preferably 10.0 or less, more preferably 5.0 or less, and even more preferably 3.0 or less.

[0525] Examples of preferred ranges for t1 / t2 include 1.5 to 10.0 and 1.5 to 5.0 and 1.5 to 3.0 and 1.8 to 10.0 and 1.8 to 5.0 and 1.8 to 3.0 and 2.0 to 10.0 and 2.0 to 5.0 and 2.0 to 3.0 and 2.0 to 3.0.

[0526] The average thickness of the first resin layer and the average thickness of the second resin layer can be calculated, for example, by selecting 20 points at any location in a cross-sectional photograph of the optical laminate taken using a scanning transmission electron microscope (STEM) and calculating based on their average values. The accelerating voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification of the STEM is preferably 1000x or more and 7000x or less.

[0527] Resin Composition

[0528] The resin layer preferably contains a cured product of a curable resin composition as the resin component. By including a cured product of a curable resin composition in the resin layer, the pencil hardness of the optical laminate can be easily improved.

[0529] The ratio of the curable resin composition to the total amount of resin component in the coating liquid for the resin layer is preferably 80% by mass or more, more preferably 90% by mass or more, further preferably 95% by mass or more, and most preferably 100% by mass.

[0530] Examples of cured products of curable resin compositions include cured products of thermosetting resin compositions and cured products of ionizing radiation-curable resin compositions. Among these, cured products of ionizing radiation-curable resin compositions that readily increase pencil hardness and readily dissolve the substrate in the uncured state are preferred.

[0531] The embodiment of the thermosetting resin composition of the optical laminate can be the same as the embodiment of the thermosetting resin composition of the anti-glare laminate of the first embodiment.

[0532] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). Examples of ionizing radiation-curable functional groups include olefinic unsaturated groups such as (meth)acryloyl, vinyl, and allyl, as well as epoxy and oxetyl groups. Compounds having olefinic unsaturated groups are preferred as ionizing radiation-curable compounds.

[0533] Ionizing rays are electromagnetic waves or charged particle beams that contain energy quanta capable of polymerizing or cross-linking molecules. They are usually ultraviolet rays or electron rays. In addition, electromagnetic waves such as X-rays and gamma rays, as well as charged particle beams such as alpha rays and ion beams can also be used.

[0534] In this specification, (meth)acryloyl group means acryloyl group or methacryloyl group. Additionally, in this specification, (meth)acrylate means acrylate or methacrylate.

[0535] As ionizing radiation-curable compounds, either monofunctional ionizing radiation-curable compounds having one ionizing radiation-curable functional group or polyfunctional ionizing radiation-curable compounds having two or more ionizing radiation-curable functional groups can be used. Furthermore, either monomers or oligomers can be used as ionizing radiation-curable compounds. It should be noted that monofunctional ionizing radiation-curable monomers tend to have better compatibility with other resin components, thus they tend to have difficulty forming island structures in the first and second resin layers. When using monofunctional ionizing radiation-curable monomers, the above characteristics should be taken into consideration.

[0536] To dissolve a portion of the substrate, form an island structure in the first and second resin layers, improve pencil hardness, and easily suppress curing shrinkage, the mixture of (a) to (c) below is preferably used as the ionizing radiation curable compound. (a) to (c) below are preferably compounds having olefinic unsaturated bond groups as ionizing radiation curable functional groups, and more preferably (meth)acrylate compounds. (Meth)acrylate compounds can also be compounds obtained by modifying a portion of the molecular skeleton using ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl groups, cyclic alkyl groups, aromatic compounds, bisphenols, etc.

[0537] (a) 2-functional ionizing radiation-curable monomers

[0538] (b) Ionizing X-ray curable monomers with three or more functions

[0539] (c) Multifunctional ionizing radiation-cured oligomers

[0540] By using a difunctional ionizing ray curable monomer containing (a) as an ionizing ray curable compound, a portion of the substrate can be easily dissolved, thus easily increasing θa1 or Pa1. However, if the amount of the difunctional ionizing ray curable monomer (a) is too large, the substrate will be over-dissolved, which may sometimes reduce the strength of the substrate or the pencil hardness of the optical laminate.

[0541] By using an ionizing ray curable monomer with three or more functions as an ionizing ray curable compound, the pencil hardness of optical laminates can be easily improved. However, if the amount of the ionizing ray curable monomer with three or more functions in (b) is too large, the hardness of the resin layer may become too high, and the bending resistance of the optical laminate may decrease.

[0542] By using a multifunctional ionizing radiation-curable oligomer containing (c) as an ionizing radiation-curable compound, it is possible to easily suppress curing shrinkage while maintaining the pencil hardness of the optical laminate. However, if the amount of the multifunctional ionizing radiation-curable oligomer containing (c) is too large, the pencil hardness of the optical laminate may sometimes decrease.

[0543] Relative to the total amount of the ionizing radiation curable compound, the amount of the difunctional ionizing radiation curable monomer of (a) is preferably 10% by mass or more and 40% by mass or less, more preferably 13% by mass or more and 30% by mass or less, and even more preferably 15% by mass or more and 25% by mass or less.

[0544] Relative to the total amount of the ionizing radiation curable compound, the amount of the ionizing radiation curable monomer with 3 or more functions in (b) is preferably 25% by mass or more and 55% by mass or less, more preferably 30% by mass or more and 50% by mass or less, and even more preferably 35% by mass or more and 45% by mass or less.

[0545] Relative to the total amount of the ionizing radiation curable compound, (c) the amount of the multifunctional ionizing radiation curable oligomer is preferably 25% by mass or more and 55% by mass or less, more preferably 30% by mass or more and 50% by mass or less, and even more preferably 35% by mass or more and 45% by mass or less.

[0546] The embodiments of the monofunctional ionizing radiation curable monomer of (a), the multifunctional ionizing radiation curable monomer of (b), and the multifunctional ionizing radiation curable oligomer of (c) of the optical laminate can be the same as the embodiments of the monofunctional ionizing radiation curable monomer of (a), the multifunctional ionizing radiation curable monomer of (b), and the multifunctional ionizing radiation curable oligomer of (c) of the anti-glare laminate of the first embodiment.

[0547] When the ionizing ray curable compound is an ultraviolet curable compound, the ionizing ray curable composition preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator, just like in the first embodiment.

[0548] The First Particle

[0549] To facilitate improvement in anti-glare performance, the resin layer preferably contains first particles with an average particle size of 0.5 μm or more. To further facilitate improvement in anti-glare performance, the second resin layer more preferably contains the aforementioned first particles.

[0550] To facilitate further improvement in anti-glare properties, it is preferable that at least 70% of the first particles are present on the second resin layer side. This proportion is preferably 80% or more, and more preferably 90% or more.

[0551] The location of the first particle in the thickness direction of the resin layer can be determined, for example, by taking a cross-sectional photograph of the optical laminate using a scanning transmission electron microscope (STEM). Furthermore, the proportion of the aforementioned number reference can be calculated from the cross-sectional photograph. It should be noted that, to improve the reliability of the values, it is preferable to obtain multiple cross-sectional photographs, set the total number of the first particle to 50 or more, and then calculate the proportion of the aforementioned number reference.

[0552] It should be noted that the number of first particles existing in both the first and second resin layers is allocated to each layer according to the area ratio of each layer. For example, if the area ratio of the first particle existing in the first resin layer is 40% and the area ratio existing in the second resin layer is 60%, 0.4 particles are allocated to the first resin layer and 0.6 particles are allocated to the second resin layer.

[0553] The preferred accelerating voltage for STEM is above 10kV and below 30kV, and the preferred STEM magnification is above 1000 times and below 7000 times.

[0554] Examples of the first particle include organic particles formed from one or more resins selected from polymethyl methacrylate, polyacrylic acid-styrene copolymer, melamine resin, polycarbonate, polystyrene, polyvinyl chloride, benzoguanamine-melamine-formaldehyde condensate, organosilicon, fluorinated resin, and polyester resin; and inorganic particles formed from one or more inorganic substances selected from silica, alumina, zirconium oxide, and titanium dioxide. Organic particles exhibit excellent dispersion stability and a relatively low specific gravity, making them preferable from the perspective of easily placing the first particle in the second resin layer.

[0555] The lower limit of the content of the first particle is preferably 0.5 parts by mass or more, more preferably 1.0 parts by mass or more, and even more preferably 1.3 parts by mass or more, and the upper limit is preferably 10.0 parts by mass or less, more preferably 5.0 parts by mass or less, and even more preferably 3.0 parts by mass or less, relative to 100 parts by mass of the resin component in the coating liquid for the resin layer.

[0556] By making the content of the first particle 0.5 parts by mass or more, the anti-glare property can be easily improved. In addition, by making the content of the first particle 10.0 parts by mass or less, the reduction in flexural strength can be easily suppressed.

[0557] Examples of preferred ranges for the content of the first particle relative to 100 parts by weight of resin include 0.5 parts by weight to 10.0 parts by weight, 0.5 parts by weight to 5.0 parts by weight, 0.5 parts by weight to 3.0 parts by weight, 1.0 parts by weight to 10.0 parts by weight, 1.0 parts by weight to 5.0 parts by weight, 1.0 parts by weight to 3.0 parts by weight, 1.3 parts by weight to 10.0 parts by weight, 1.3 parts by weight to 5.0 parts by weight, and 1.3 parts by weight to 3.0 parts by weight.

[0558] To easily improve anti-glare performance, the average particle size of the first particle is preferably 0.8 μm or more, and more preferably 1.0 μm or more.

[0559] In order to easily suppress the decrease in bending resistance, the average particle size of the first particle is preferably 3.0 μm or less, more preferably 2.7 μm or less, and even more preferably 2.5 μm or less.

[0560] Examples of preferred ranges for the average particle size of the first particle include 0.8 μm to 3.0 μm, 0.8 μm to 2.7 μm, 0.8 μm to 2.5 μm, 1.0 μm to 3.0 μm, 1.0 μm to 2.7 μm, and 1.0 μm to 2.5 μm.

[0561] The average particle size of the first particle can be calculated, for example, using the same method as the anti-glare laminate of the first embodiment.

[0562] Regarding D1, which represents the average particle size of the first particle, and t2, which represents the average thickness of the second resin layer, t2-D1 is preferably -0.5 μm or more, and preferably 2.0 μm or less.

[0563] When t2-D1 is -0.5μm or more, the surface of the optical laminate can be easily given an uneven shape through the first particle, thus easily improving the anti-glare performance. t2-D1 is more preferably 0μm or more, and even more preferably 0.1μm or more.

[0564] When t2-D1 is 2.0 μm or less, the first particle is less likely to protrude from the surface of the second resin layer, thereby easily improving scratch resistance. t2-D1 is more preferably 1.5 μm or less, and even more preferably 0.8 μm or less.

[0565] Examples of preferred ranges for t2-D1 include -0.5μm to 2.0μm, -0.5μm to 1.5μm, -0.5μm to 0.8μm, 0μm to 2.0μm, 0μm to 1.5μm, 0μm to 0.8μm, 0.1μm to 2.0μm, 0.1μm to 1.5μm, and 0.1μm to 0.8μm.

[0566] Inorganic Particles

[0567] The resin layer can contain inorganic microparticles. By including relatively heavy inorganic microparticles in the resin layer, the first particle is less likely to sink to the bottom of the resin layer, thus making it easier for the first particle to be located in the second resin layer. In addition, the inorganic microparticles can improve the dispersibility of the first particle and easily suppress the decrease in flexural strength.

[0568] The implementation of the average particle size and type of inorganic particles in the optical laminate can be the same as the implementation of the average particle size and type of inorganic particles in the anti-glare laminate of the first embodiment.

[0569] The content of inorganic microparticles is preferably 0.1 parts by mass or more, more preferably 0.5 parts by mass or more, and even more preferably 0.7 parts by mass or more, and the upper limit is preferably 5.0 parts by mass or less, more preferably 3.0 parts by mass or less, and even more preferably 2.0 parts by mass or less, relative to 100 parts by mass of the resin component in the coating liquid for the resin layer.

[0570] By making the content of inorganic microparticles 0.1 parts by mass or more, it is easy to place the first particle in the second resin layer. In addition, by making the content of inorganic microparticles 5.0 parts by mass or less, it is possible to prevent the first particle from floating excessively on the top of the resin layer, thus easily suppressing the reduction of flexural strength.

[0571] Examples of preferred ranges for the content of inorganic particles relative to 100 parts by weight of resin include 0.1 to 5.0 parts by weight, 0.1 to 3.0 parts by weight, 0.1 to 2.0 parts by weight, 0.5 to 5.0 parts by weight, 0.5 to 3.0 parts by weight, 0.5 to 2.0 parts by weight, 0.7 to 5.0 parts by weight, 0.7 to 3.0 parts by weight, and 0.7 to 2.0 parts by weight.

[0572] Similar to the first embodiment, the coating liquid for the resin layer may contain additives as needed.

[0573] Solvent

[0574] The coating liquid for the resin layer preferably contains a solvent.

[0575] As a solvent, it is preferable to choose a solvent that can dissolve the substrate. The easier it is to dissolve the substrate, the more likely the values ​​of θa1 and Pa1 will increase. However, if the substrate is over-dissolved, the strength of the substrate will decrease. Therefore, it is preferable to select an appropriate solvent according to the type of substrate.

[0576] Furthermore, solvent selection considers not only the solubility in the substrate but also the inherent evaporation rate of the solvent. The solvent evaporation rate can also be controlled by the drying conditions. For example, increasing the drying temperature accelerates the solvent evaporation rate. Additionally, increasing the drying air velocity also accelerates the solvent evaporation rate.

[0577] If the solvent dries slowly, the substrate dissolves, and θa1 and Pa1 tend to increase. Furthermore, if the solvent dries slowly or at a high temperature, the movement of resin components between the first and second resin layers becomes more intense, and θa2 and Pa2 tend to increase.

[0578] Therefore, solvents should be selected with consideration of the solubility of the substrate, evaporation rate, and drying conditions.

[0579] The implementation of the type of solvent for the optical laminate can be the same as the implementation of the type of solvent for the anti-glare laminate in the first embodiment.

[0580] Acrylic resin substrates are readily soluble in solvents. Therefore, when using acrylic resin substrates, solvents with inherently fast evaporation rates are preferred.

[0581] In this specification, a solvent with a fast evaporation rate refers to a solvent whose evaporation rate is 100 or higher when the evaporation rate of butyl acetate is set to 100. Conversely, a solvent with a slow evaporation rate refers to a solvent whose evaporation rate is less than 100 when the evaporation rate of butyl acetate is set to 100.

[0582] For solvents with fast evaporation rates, the evaporation rate is more preferably 120 to 450, and even more preferably 140 to 400.

[0583] Examples of solvents with fast evaporation rates include isopropanol (evaporation rate 150), methyl isobutyl ketone (evaporation rate 160), toluene (evaporation rate 200), and methyl ethyl ketone (evaporation rate 370).

[0584] Solvents with fast evaporation rates are preferably 75% to 85% of the total solvent mass.

[0585] Furthermore, to facilitate the formation of island structures in the first and second resin layers, the solvent preferably possesses inherent properties such as slow evaporation rate, high polarity, and large molecular weight. Solvents with these characteristics increase the viscosity of the coating solution, making it prone to gelation. Therefore, solvents with these characteristics can easily reduce the compatibility of the coating solution, thus facilitating the formation of island structures. Examples of solvents possessing these characteristics include cyclohexanone and diacetone alcohol.

[0586] Solvents with slow evaporation rates, high polarity, and large molecular weight are preferably 15% to 25% by mass of the total solvent volume.

[0587] Drying conditions

[0588] When forming a resin layer from a resin layer using a coating liquid, it is preferable to control the drying conditions.

[0589] Furthermore, the optical laminate of the present invention preferably dries the coating liquid for the resin layer in two stages. Specifically, it is preferable to reduce the drying air velocity in the first stage of drying and increase the drying air velocity in the second stage of drying. During the first stage of drying, a first resin layer can be formed from a region containing resin components dissolved from the substrate as the main component and a small amount of resin components containing the coating liquid for the resin layer, and then a second resin layer can be formed from a region containing a small amount of resin components dissolved from the substrate and a small amount of resin components containing the coating liquid for the resin layer as the main component. Furthermore, by increasing the drying temperature in the first stage, the resin components are more easily mobile, thereby facilitating the formation of island structures.

[0590] Furthermore, by implementing the second stage of drying, excessive dissolution of the substrate can be suppressed, thus easily preventing θa1 and Pa1 from becoming excessive.

[0591] Furthermore, in both the first and second stages of drying, it is preferable to control the drying time. A longer drying time for the resin coating liquid means a longer period until the resin component of the resin coating liquid is irradiated with ionizing rays. In other words, a longer drying time for the resin coating liquid means that the resin component of the resin coating liquid remains uncured and fluid for an extended period. Therefore, if the drying time for the resin coating liquid is longer, the movement of the resin component between the first and second resin layers becomes more vigorous, and θa2 and Pa2 tend to increase, making it difficult to satisfy conditions 1B and 2B.

[0592] Drying conditions can be controlled by the drying temperature and the air velocity within the dryer. The preferred ranges for drying temperature and air velocity vary depending on the composition of the coating liquid used for the resin layer, and therefore cannot be generalized. The following conditions are preferred.

[0593] <Stage 1 Drying>

[0594] The preferred drying temperature is 75℃ to 95℃, and the preferred drying air velocity is 1m / s to 10m / s. The preferred drying time is 20 seconds to 40 seconds.

[0595] <Stage 2 Drying>

[0596] The preferred drying temperature is 75℃ to 95℃, and the preferred drying air velocity is 15m / s to 30m / s. The preferred drying time is 20 seconds to 40 seconds.

[0597] In order to dissolve a portion of the substrate using the coating liquid for the resin layer and to facilitate thorough mixing of the components dissolved from the substrate with the coating liquid for the resin layer, irradiation with ionizing rays is preferably performed after the coating liquid has dried.

[0598] <Condition 1B, Condition 2B>

[0599] The optical laminate of the present invention needs to satisfy either condition 1B or condition 2B below. The optical laminate of the present invention only needs to satisfy at least one of condition 1B and condition 2B, preferably both.

[0600] <Condition 1B>

[0601] The average tilt angle θa1 of the surface representing the resin layer side of the substrate and the average tilt angle θa2 of the surface representing the second resin layer side of the first resin layer satisfy the relationship θa2<θa1.

[0602] <Condition 2B>

[0603] Pa1, which represents the arithmetic mean height of the surface of the resin layer side of the substrate, and Pa2, which represents the arithmetic mean height of the surface of the second resin layer side of the first resin layer, satisfy the relationship Pa2 < Pa1.

[0604] -Condition 1B-

[0605] If the relationship θa2 < θa1 is not satisfied, it is difficult to improve the initial tightness because θa1 is small, or it is difficult to suppress the change in the clarity of the transmitted image after the lightfastness test because θa2 is large.

[0606] The reason for the change in transmitted image sharpness before and after the lightfastness test is believed to be the change in the refractive index difference at the interface between the first and second resin layers. In the optical laminate of the present invention, not only the interface between the first and second resin layers exists, but also the interface between the substrate and the first resin layer. The substrate (especially an acrylic resin substrate) is relatively difficult to modify through the lightfastness test. On the other hand, the resin component of the coating liquid in the resin layer is relatively easy to modify through the lightfastness test. Therefore, the refractive index of the second resin layer, which has a low resin content in the substrate, is prone to change before and after the lightfastness test. On the other hand, the refractive index of the substrate and the first resin layer, which contains a large amount of substrate resin, is not easily changed before and after the lightfastness test. Therefore, when θa2 is large and the relationship θa2 < θa1 is not satisfied, it is considered difficult to suppress the change in transmitted image sharpness after the lightfastness test.

[0607] -Condition 2B-

[0608] If the relationship Pa2 < Pa1 is not satisfied, it is difficult to improve the initial tightness due to the small Pa1, or it is difficult to suppress the change in the clarity of the transmitted image after the lightfastness test due to the large Pa2.

[0609] The reason why it is difficult to suppress the change in the clarity of the transmitted image after the lightfastness test when Pa2 is large and the relationship Pa2 < Pa1 is not satisfied can be considered as the same reason as in condition 1B.

[0610] To facilitate improvement of initial adhesion, θa1 is preferably 5.0 degrees or more, more preferably 8.0 degrees or more, and even more preferably 10.0 degrees or more. To facilitate improvement of pencil hardness, θa1 is preferably 20.0 degrees or less, more preferably 18.0 degrees or less, and even more preferably 17.0 degrees or less.

[0611] Examples of preferred ranges for θa1 include 5.0 degrees to 20.0 degrees, 5.0 degrees to 18.0 degrees, 5.0 degrees to 17.0 degrees, 8.0 degrees to 20.0 degrees, 8.0 degrees to 18.0 degrees, 8.0 degrees to 17.0 degrees, 10.0 degrees to 20.0 degrees, 10.0 degrees to 18.0 degrees, and 10.0 degrees to 17.0 degrees.

[0612] In order to easily suppress changes in the clarity of the transmitted image after the lightfastness test, θa2 is preferably 10.0 degrees or less, more preferably 8.0 degrees or less, further preferably 6.0 degrees or less, and even more preferably 4.0 degrees or less.

[0613] To facilitate improved sealing, θa2 is preferably greater than 0 degrees, more preferably greater than 1.0 degrees, and even more preferably greater than 2.0 degrees.

[0614] Examples of preferred ranges for θa2 include: greater than 0 degrees and less than 10.0 degrees; greater than 0 degrees and less than 8.0 degrees; greater than 0 degrees and less than 6.0 degrees; greater than 0 degrees and less than 4.0 degrees; greater than 1.0 degrees and less than 10.0 degrees; greater than 1.0 degrees and less than 8.0 degrees; greater than 1.0 degrees and less than 6.0 degrees; greater than 1.0 degrees and less than 4.0 degrees; greater than 2.0 degrees and less than 10.0 degrees; greater than 2.0 degrees and less than 8.0 degrees; greater than 2.0 degrees and less than 6.0 degrees; and greater than 2.0 degrees and less than 4.0 degrees.

[0615] To facilitate improvement of initial adhesion, Pa1 is preferably 0.05 μm or more, more preferably 0.07 μm or more, and even more preferably 0.10 μm or more. To facilitate improvement of pencil hardness, Pa1 is preferably 0.25 μm or less, more preferably 0.23 μm or less, and even more preferably 0.20 μm or less.

[0616] Examples of preferred ranges for Pa1 include 0.05 μm to 0.25 μm, 0.05 μm to 0.23 μm, 0.05 μm to 0.20 μm, 0.07 μm to 0.25 μm, 0.07 μm to 0.23 μm, 0.07 μm to 0.20 μm, 0.10 μm to 0.25 μm, 0.10 μm to 0.23 μm, and 0.10 μm to 0.20 μm.

[0617] In order to easily suppress changes in the clarity of the transmitted image after the lightfastness test, Pa2 is preferably 0.15 μm or less, more preferably 0.13 μm or less, even more preferably 0.10 μm or less, and even more preferably 0.06 μm or less.

[0618] To facilitate improved sealing, Pa2 is preferably 0.02 μm or more, more preferably 0.04 μm or more, and even more preferably 0.05 μm or more.

[0619] Examples of preferred ranges for Pa2 include 0.02 μm to 0.15 μm, 0.02 μm to 0.13 μm, 0.02 μm to 0.10 μm, 0.04 μm to 0.15 μm, 0.04 μm to 0.13 μm, 0.04 μm to 0.10 μm, 0.05 μm to 0.15 μm, 0.05 μm to 0.13 μm, and 0.05 μm to 0.10 μm.

[0620] θa1 and θa2, as well as Pa1 and Pa2, can be determined, for example, as follows.

[0621] (1) Take cross-sectional photographs of the optical laminate using a scanning transmission electron microscope (STEM). The accelerating voltage of the STEM is preferably above 10kV and below 30kV, and the magnification of the STEM is preferably above 5000x and below 10000x.

[0622] (2) Obtain the edge lines of the interface between the substrate and the resin layer, and the edge lines of the interface between the first resin layer and the second resin layer from the cross-sectional photograph, and obtain height data. Specifically, as in steps (a) to (l) of the first embodiment. The interface between the substrate and the resin layer corresponds to the surface of the substrate on the resin layer side. The interface between the first resin layer and the second resin layer corresponds to the surface of the first resin layer on the second resin layer side.

[0623] (3) Based on the height data points, calculate the average tilt angle and the arithmetic mean height according to the steps (m) to (q) of the first embodiment.

[0624] In this specification, θa1 and θa2, as well as Pa1 and Pa2, refer to the average values ​​of the measurements from 20 samples.

[0625] In order to make θa1 and θa2, as well as Pa1 and Pa2, fall within the aforementioned ranges, it is important that, as described above, a portion of the substrate is dissolved using the coating liquid for the resin layer, the composition of the coating liquid for the resin layer is appropriately prepared, and the drying conditions of the coating liquid for the resin layer are within an appropriate range.

[0626] [Polarizing filter]

[0627] The polarizer of the present invention is a polarizer having a polarizing element, a first transparent protective plate disposed on one side of the polarizing element, and a second transparent protective plate disposed on the other side of the polarizing element, wherein at least one of the first transparent protective plate and the second transparent protective plate is any one of the anti-glare laminates or optical laminates selected from the anti-glare laminate of the first embodiment of the present invention, the anti-glare laminate of the second embodiment of the present invention, and the optical laminate of the present invention.

[0628] Polarizers are used, for example, to impart antireflective properties by combining a polarizer and a λ / 4 retardation plate. In this case, a λ / 4 retardation plate is disposed on the display element of the image display device, and a polarizer is disposed closer to the observer than the λ / 4 retardation plate.

[0629] When a polarizer is used in a liquid crystal display device, it functions as a shutter for the liquid crystal. In this case, the liquid crystal display device is configured with a lower polarizer, a liquid crystal display element, and an upper polarizer in sequence, with the absorption axis of the polarizing element of the lower polarizer orthogonal to the absorption axis of the polarizing element of the upper polarizer. In the above configuration, it is preferable to use the polarizer of the present invention as the upper polarizer.

[0630] <Transparent Protective Panel>

[0631] In the polarizer of the present invention, at least one of the first transparent protective plate and the second transparent protective plate is any one of the anti-glare laminates or optical laminates selected from the first embodiment of the present invention, the second embodiment of the present invention, and the optical laminates of the present invention. A preferred embodiment is one in which the transparent protective plate on the light-emitting side of the first and second transparent protective plates is any one of the anti-glare laminates or optical laminates selected from the first embodiment of the present invention, the second embodiment of the present invention, and the optical laminates of the present invention. The anti-glare laminates and optical laminates are preferably configured such that the substrate side is the polarizing element side.

[0632] When one of the first transparent protective plate and the second transparent protective plate is any one of the anti-glare laminates selected from the first embodiment of the present invention, the second embodiment of the present invention, and the optical laminates of the present invention, the other transparent protective plate is not particularly limited, but an optically isotropic transparent protective plate is preferred.

[0633] In this specification, optical isotropy refers to an in-plane phase difference of 20 nm or less, preferably 10 nm or less, and more preferably 5 nm or less. Acrylic films and triacetyl cellulose (TAC) films readily impart optical isotropy.

[0634] <Polarization element>

[0635] Examples of polarizing elements include sheet-type polarizing elements such as polyvinyl alcohol films, polyvinyl alcohol formal films, polyvinyl alcohol acetal films, and ethylene-vinyl acetate copolymer saponified films, which are dyed with iodine and stretched; wire grid-type polarizing elements composed of a large number of parallel metal lines; coated polarizing elements coated with lyotropic liquid crystals or dichroic host-guest materials; and multilayer thin film polarizing elements. These polarizing elements can also be reflective polarizing elements that have the function of reflecting non-transmissive polarizing components.

[0636] <Size, shape, etc.>

[0637] The size and shape of the polarizer of the present invention can be implemented in the same way as the size and shape of the anti-glare laminate or the optical laminate of the present invention described above.

[0638] [Image display device]

[0639] The image display device of the present invention has an anti-glare laminate selected from the anti-glare laminate of the first embodiment of the present invention, the anti-glare laminate of the second embodiment of the present invention, and the optical laminate of the present invention on the display element.

[0640] Figure 4 , Figure 7 , Figure 10 This is a cross-sectional view illustrating an embodiment of the image display device 500 of the present invention. Figure 4 The image display device 500 has an anti-glare laminate 100A according to the first embodiment of the present invention on the display element 200. Figure 7 The image display device 500 has an anti-glare laminate 100B according to the second embodiment of the present invention on the display element 200. Figure 10 The image display device 500 has the optical laminate 100C of the present invention on the display element 200. Within the image display device, the anti-glare laminate or optical laminate is preferably configured such that the substrate side faces the display element side.

[0641] Examples of display elements include liquid crystal displays (LCDs); EL displays (organic EL displays and inorganic EL displays); plasma displays; displays using QD (quantum dot) technology; and LED displays such as small LEDs and micro LEDs. These display elements can also incorporate touch panel functionality within their internal components.

[0642] Liquid crystal displays (LCDs) can be displayed in various ways, including IPS, VA, multi-domain, OCB, STN, and TSTN. When the display element is an LCD, a backlight is required. The backlight is positioned on the side of the LCD element opposite to the side where the anti-glare layer or optical layer is located.

[0643] Alternatively, the image display device of the present invention can also be an image display device with a touch panel, having a touch panel between the display element and the anti-glare laminate. In this case, it is preferable to arrange the anti-glare laminate or optical laminate on the outermost surface of the image display device with the touch panel, and to arrange the substrate side of the anti-glare laminate or optical laminate toward the display element side.

[0644] There is no particular limitation on the size of the image display device, but it is preferred that the maximum diameter of the effective display area is more than 2 inches and less than 500 inches.

[0645] The effective display area of ​​an image display device refers to the area capable of displaying an image. For example, in the case where the image display device has a housing surrounding the display element, the area inside the housing becomes the effective image area.

[0646] The maximum diameter of the effective image region refers to the maximum length that connects any two points within the effective image region. For example, if the effective image region is rectangular, the diagonal of the rectangle becomes the maximum diameter. Conversely, if the effective image region is circular, the diameter of the circle becomes the maximum diameter.

[0647] The anti-glare laminate of the first embodiment and the anti-glare laminate of the second embodiment of the present invention exhibit excellent bending resistance. Therefore, an image display device having the anti-glare laminate of the first embodiment or the anti-glare laminate of the second embodiment of the present invention on a display element is preferably a foldable image display device or a rollable image display device.

[0648] Example

[0649] The invention will now be described in more detail through examples, but the invention is not limited to these examples in any way. It should be noted that, unless otherwise specified, "parts" and "%" are based on mass.

[0650] <Example of the anti-glare laminate according to the first embodiment>

[0651] 1. Measurement and evaluation

[0652] The anti-glare laminates of the Examples and Comparative Examples were measured and evaluated as follows. It should be noted that the atmosphere for each measurement and evaluation was set to a temperature of 23±5°C and a relative humidity of 40% to 65%. Furthermore, before each measurement and evaluation, the sample was exposed to the above atmosphere for at least 30 minutes. The results are shown in Table 2. Since the anti-glare laminates of Comparative Examples 1-7 have a single-layer resin structure, the values ​​for the second resin layer in Table 2 are marked as "-".

[0653] 1-1. Average thickness of the first resin layer and the second resin layer

[0654] According to the description in the main text of the specification, samples of the anti-glare laminates of the examples and comparative examples with exposed cross-sections were prepared. Twenty points were selected at any position from the cross-sectional photographs of the above samples taken using a scanning transmission electron microscope, and the average thickness t1 of the first resin layer and the average thickness t2 of the second resin layer were calculated based on their average values.

[0655] 1-2. Position of the first particle

[0656] According to the description in the main text of the specification, samples of the anti-glare laminates of the embodiments and comparative examples with exposed cross-sections were prepared. The proportion of the number of first particles existing across the first and second resin layers was calculated from cross-sectional photographs of the samples taken using a scanning transmission electron microscope. Multiple cross-sectional photographs were obtained in calculating this proportion until the total number of first particles exceeded 50. Simultaneously, the proportion of the number of first particles existing only in the first resin layer and the proportion of the number of first particles existing only in the second resin layer were calculated.

[0657] 1-3. The average tilt angle of the resin layer side surface of the substrate, and the arithmetic mean height of the resin layer side surface of the substrate.

[0658] According to the description in the main text of the specification, samples of the anti-glare laminates of the embodiments and comparative examples with exposed cross sections were prepared. Based on cross-sectional photographs of the samples taken using a scanning transmission electron microscope, and according to the description in the main text of the specification, the average tilt angle of the resin layer side surface of the substrate and the arithmetic mean height of the resin layer side surface of the substrate were calculated.

[0659] 1-4. Indentation Hardness

[0660] According to the description in the instruction manual, samples with exposed cross-sections of the anti-glare laminates of the examples and comparative examples were prepared. Next, using a measuring apparatus (Bruker, model: TI950), the indentation hardness at the midpoint of the thickness direction of the first resin layer and the midpoint of the thickness direction of the second resin layer of the samples were measured according to the description in the instruction manual. The average value of the measured values ​​of 20 samples was taken as H1 and H2 for each example and comparative example.

[0661] 1-5. Total light transmittance (Tt) and haze (Hz)

[0662] The anti-glare laminates of the examples and comparative examples were cut into 10cm square pieces. After visually confirming that there were no abnormalities such as dust or scratches at the cut locations, random locations were selected. Using a haze meter (HM-150, Murakami Color Technology Research Institute), the total light transmittance of each sample according to JIS K7361-1:1997 and the haze according to JIS K7136:2000 were measured.

[0663] It should be noted that, in order to stabilize the light source, after turning on the power switch of the device, wait for more than 15 minutes, and perform calibration without making any settings at the inlet opening (the part where the sample is set). Then, set the sample at the inlet opening and perform the measurement. The light incident surface is the substrate side.

[0664] 1-6. Bending resistance

[0665] The anti-glare laminates of the examples and comparative examples were subjected to a bending resistance test based on the cylindrical mandrel method specified in JIS K5600-5-1:1999. The diameter of the mandrel was gradually reduced, and the diameter of the mandrel at which the anti-glare laminate initially cracked is shown in Table 2. A diameter of 5 mm or less was considered acceptable. When winding the anti-glare laminate onto the mandrel, the substrate side was made to be the mandrel side.

[0666] 1-7. Pencil Hardness

[0667] Samples of the anti-glare laminates of the examples and comparative examples were prepared by cutting them into 50mm × 100mm sizes. The pencil hardness of the upper surface of the resin layer of the above samples was measured according to JISK 5600-5-4:1999, under a load of 500g and a speed of 1.4mm / s.

[0668] The pencil hardness was measured using a pencil hardness tester from Toyo Seiki Manufacturing Co., Ltd. (model: NP type pencil scratch coating hardness tester). Repair tape (3M, model "810-3-18") was used to attach both ends of the cut sample to the base of the pencil hardness tester. Five pencil hardness tests were performed, and the hardness at which no scratches or other visual abnormalities were observed in three or more tests was taken as the pencil hardness value for each sample. For example, if a 2H pencil was used for five tests, and no visual abnormalities were observed in three of them, the pencil hardness of the anti-glare laminate was 2H. Regarding visual abnormalities, discoloration was excluded, and scratches and dents were checked. A pencil hardness of 2H or higher was considered acceptable.

[0669] 1-8. Anti-glare

[0670] A sample (sample size: 10cm x 10cm) was fabricated by bonding a black plate (KURARAY, Comoglass DFA2CG 502K (Black) series, 0% total light transmittance, 2mm thickness, refractive index 1.49) to the substrate side of the anti-glare laminate of the examples and comparative examples, separated by a 25μm thick transparent adhesive layer (PANAC Corporation, trade name "PANACLEAN PD-S1"), with the substrate being a substrate. Under bright ambient light (illuminance of 500 lux to 1000 lux on the first main surface of the sample; illumination: Hf32 type straight tube three-wavelength neutral white fluorescent lamp), the sample was viewed from a height of 50cm above the center of the first main surface. Twenty subjects evaluated the degree to which the observer's own reflection was not noticeable, based on the following criteria. The illumination position during evaluation was 2m above a horizontal platform in the vertical direction. The subjects were healthy individuals in their 30s with visual acuity of 0.7 or better.

[0671] A: There were 14 or more people who gave good answers.

[0672] B: 7 to 13 people answered well.

[0673] C: Fewer than 6 people answered well.

[0674] 2. Fabrication of anti-glare laminates

[0675] [Example 1-1]

[0676] (Substrate manufacturing)

[0677] The copolymer of methyl methacrylate and methyl acrylate was compounded at 260°C using a twin-screw extruder to obtain a granular composition (glass transition temperature: 134°C). The resulting granular composition was melt-extruded using a T-die (T-die temperature: 260°C) and discharged onto a cooling roller at 130°C. Subsequently, it was biaxially stretched sequentially in both the longitudinal and transverse directions at a stretch ratio of 1.5 times at a stretching temperature of 145°C. Cooling was then performed to obtain an acrylic resin matrix with a thickness of 40 μm.

[0678] (Formation of the resin layer)

[0679] On the aforementioned acrylic resin substrate, a Mayer rod coating method was used at a rate of 6.0 g / m². 2 After coating with the resin layer of Example 1-1 in Table 1, the coating liquid was applied and dried with hot air at a wind speed of 15 m / s and a temperature of 100°C for 60 seconds. Then, under a nitrogen atmosphere with an oxygen concentration of less than 200 ppm, the cumulative light intensity was increased to 100 mJ / cm². 2 The resin coating liquid is irradiated with ultraviolet light, thereby curing the ionizing radiation-curable resin composition to form a first resin layer and a second resin layer, resulting in the anti-glare laminate of Example 1-1. In this specification, coating amount refers to the amount of coating after drying.

[0680] [Examples 1-2 to 1-4], [Comparative Examples 1-1 to 1-2, 1-5 to 1-7]

[0681] By changing the composition of the coating liquid for the resin layer, the coating amount of the coating liquid for the resin layer, and the drying conditions of the coating liquid for the resin layer to the composition described in Table 1, the anti-glare laminates of Examples 1-2 to 1-4 and Comparative Examples 1-1 to 1-2, 1-5 to 1-7 were obtained in the same manner as in Example 1-1. It should be noted that the resin layer of the anti-glare laminate of Comparative Examples 1-7 is a single-layer structure of the first resin layer.

[0682] [Comparative Examples 1-3]

[0683] On the aforementioned acrylic resin substrate, a Mayer rod coating method was used at a rate of 6.0 g / m². 2The coating amount of the first resin layer in Comparative Examples 1-3 of Table 1 was determined by coating with the coating liquid and then dried with hot air at a wind speed of 15 m / s and a temperature of 100°C for 60 seconds. Next, under a nitrogen atmosphere with an oxygen concentration of less than 200 ppm, the cumulative light intensity was determined to be 50 mJ / cm². 2 The resin composition of the first resin layer coating liquid is cured by irradiating it with ultraviolet light, thereby forming the first resin layer.

[0684] Next, on the first resin layer, a Mayer rod coating method was used at a concentration of 2.0 g / m². 2 The second resin layer of Comparative Examples 1-3 in Table 1 was coated with the coating liquid and then dried with hot air at a wind speed of 15 m / s and a temperature of 70°C for 60 seconds. Next, under a nitrogen atmosphere with an oxygen concentration of less than 200 ppm, the cumulative light intensity was 100 mJ / cm². 2 The ionizing radiation-curable resin composition of the second resin layer coating liquid is cured by irradiating with ultraviolet light to form the second resin layer, thereby obtaining the anti-glare laminates of Comparative Examples 1-3.

[0685] [Comparative Examples 1-4]

[0686] By changing the composition of the coating liquid for the first and second resin layers, the coating amount of the coating liquid for the first and second resin layers, and the drying conditions of the coating liquid for the first and second resin layers to the composition described in Table 1, the anti-glare laminates of Comparative Examples 1-4 were obtained in the same manner as Comparative Examples 1-3.

[0687] [Table 1]

[0688]

[0689] In Table 1, the 6-functional urethane acrylate oligomer represents the urethane acrylate oligomer from Mitsubishi Chemical Co., Ltd. (trade name: UV-7600B, weight average molecular weight: 1400), the 2-functional acrylate monomer represents tetraethylene glycol diacrylate, the 3-functional acrylate monomer represents pentaerythritol triacrylate, the monofunctional acrylate monomer represents 4-hydroxybutyl acrylate, and the photopolymerization initiator represents the trade name "Omnirad 184" from IGM Resins BV.

[0690]

[0691] The results in Table 2 confirm that the pencil hardness, bending resistance and anti-glare properties of the anti-glare laminate of the first embodiment are good.

[0692] <Example of the anti-glare laminate according to the second embodiment>

[0693] 3. Measurement and Evaluation

[0694] The anti-glare laminates of the examples and comparative examples were measured and evaluated as follows. It should be noted that the atmosphere for each measurement and evaluation was set to a temperature of 23±5°C and a relative humidity of 40% to 65%. Furthermore, before each measurement and evaluation, the sample was exposed to the above atmosphere for at least 30 minutes. The results are shown in Table 4.

[0695] 3-1. The average tilt angle of the resin layer side surface of the substrate, and the arithmetic mean height of the resin layer side surface of the substrate.

[0696] According to the description in the main text of the specification, samples of the anti-glare laminates of the embodiments and comparative examples with exposed cross sections were prepared. Based on cross-sectional photographs of the samples taken using a scanning transmission electron microscope, and according to the description in the main text of the specification, the average tilt angle of the resin layer side surface of the substrate and the arithmetic mean height of the resin layer side surface of the substrate were calculated.

[0697] 3-2. Position of the first particle

[0698] According to the description in the main text of the specification, samples of the anti-glare laminates of the examples and comparative examples with exposed cross-sections were prepared. The proportion of the number of first particles present in the second region was calculated from cross-sectional photographs of the samples taken using a scanning transmission electron microscope. Multiple cross-sectional photographs were obtained in calculating this proportion until the total number of first particles exceeded 50.

[0699] 3-3. Average thickness of the resin layer

[0700] According to the description in the main text of the specification, samples of the anti-glare laminates of the examples and comparative examples with exposed cross-sections were prepared. Twenty points were selected at any position from the cross-sectional photographs of the above samples taken using a scanning transmission electron microscope, and the average thickness t of the resin layer was calculated based on the average value.

[0701] 3-4. Total light transmittance (Tt) and haze (Hz)

[0702] The total light transmittance and haze of the anti-glare laminates of the Examples and Comparative Examples were measured using the same methods as described in 1-5 above.

[0703] 3-5. Bending resistance

[0704] Using the same method as described in 1-6 above, the anti-glare laminates of the embodiments and comparative examples were subjected to bending resistance tests based on the cylindrical mandrel method.

[0705] 3-6. Pencil hardness

[0706] The pencil hardness of the upper surface of the resin layer of the anti-glare laminate of the Examples and Comparative Examples was measured using the same method as described in 1-7 above.

[0707] 3-7. Anti-glare

[0708] The anti-glare properties of the anti-glare laminates of the embodiments and comparative examples were evaluated using the same methods as described in 1-8 above.

[0709] 4. Fabrication of anti-glare laminates

[0710] [Example 2-1]

[0711] (Substrate manufacturing)

[0712] The copolymer of methyl methacrylate and methyl acrylate was compounded at 260°C using a twin-screw extruder to obtain a granular composition (glass transition temperature: 134°C). The resulting granular composition was melt-extruded using a T-die (T-die temperature: 260°C) and discharged onto a cooling roller at 130°C. Subsequently, it was biaxially stretched sequentially in both the longitudinal and transverse directions at a stretch ratio of 1.5 times at a stretching temperature of 145°C. Cooling was then performed to obtain an acrylic resin matrix with a thickness of 40 μm.

[0713] (Formation of the resin layer)

[0714] On the aforementioned acrylic resin substrate, a Mayer rod coating method was used at a rate of 6.0 g / m². 2 After applying the coating liquid to the resin layer of Example 2-1 in Table 3, the first stage of drying was performed by drying with hot air at a wind speed of 1 m / s and a temperature of 70°C for 30 seconds. Then, the coating liquid was dried with hot air at a wind speed of 20 m / s and a temperature of 70°C for 30 seconds to perform the second stage of drying. Next, under a nitrogen atmosphere with an oxygen concentration of less than 200 ppm, the cumulative light intensity was 100 mJ / cm². 2 The resin layer coating liquid is cured by irradiating it with ultraviolet light, thereby forming a resin layer and obtaining the anti-glare laminate of Example 2-1. In this specification, the coating amount refers to the coating amount after drying.

[0715] [Examples 2-2 to 2-4], [Comparative Examples 2-1 to 2-4]

[0716] By changing the composition of the coating liquid for the resin layer, the coating amount of the coating liquid for the resin layer, and the drying conditions of the coating liquid for the resin layer to the composition described in Table 3, the anti-glare laminates of Examples 2-2 to 2-4 and Comparative Examples 2-1 to 2-4 were obtained in the same manner as in Example 2-1.

[0717]

[0718] In Table 3, the 6-functional urethane acrylate oligomer represents the urethane acrylate oligomer from Mitsubishi Chemical Co., Ltd. (trade name: UV-7600B, weight average molecular weight: 1400), the 2-functional acrylate monomer represents tetraethylene glycol diacrylate, the 3-functional acrylate monomer represents pentaerythritol triacrylate, the 4-functional acrylate monomer represents pentaerythritol tetraacrylate, the monofunctional acrylate monomer represents 4-hydroxybutyl acrylate, and the photopolymerization initiator represents the trade name "Omnirad 184" from IGMresins BV.

[0719] [Table 4]

[0720] Table 4

[0721]

[0722] The results in Table 4 confirm that the pencil hardness, bending resistance and anti-glare properties of the anti-glare laminate in the embodiment are good.

[0723] On the other hand, in the anti-glare laminates of Comparative Examples 2-1 and 2-2, more than 70% of the number of the first particle is absent from the second region. In the anti-glare laminate of Comparative Example 2-1, although more than 70% of the number of the first particle is absent from the second region, the content of the first particle is high, therefore the anti-glare performance is at a satisfactory level. However, because the anti-glare laminate of Comparative Example 2-1 has a high content of the first particle, the interface between the first particle and the resin layer increases, leading to reduced flexural strength, thus failing to suppress the decrease in the flexural strength of the anti-glare laminate. In the anti-glare laminate of Comparative Example 2-2, more than 70% of the number of the first particle is absent from the second region, and the content of the first particle is low, therefore the anti-glare performance cannot be improved. For the anti-glare laminates of Comparative Examples 2-1 and 2-2, the reason why more than 70% of the number of the first particles are not present in the second region is that, due to the strong initial drying strength, the solvent evaporates before sufficient convection of the coating liquid is generated, making it difficult for the first particles to float above the resin layer by convection.

[0724] The optical laminates of Comparative Examples 2-3 have large average tilt angles and arithmetic mean heights of the substrate. That is, in Comparative Examples 2-3, due to the large amount of substrate components dissolving into the resin layer, the hardness of the resin layer decreases, failing to improve pencil hardness. It is believed that in Comparative Examples 2-3, due to the high proportion of monofunctional monomers, excessive dissolution of the substrate occurs, resulting in larger average tilt angles and arithmetic mean heights of the substrate.

[0725] In Comparative Examples 2-4, the optical laminates exhibited poor adhesion between the substrate and the resin layer due to the small average tilt angle and arithmetic mean height of the substrate, thus failing to suppress the decrease in flexural strength. It is believed that since the optical laminates of Comparative Examples 2-4 do not contain monofunctional monomers or highly polar methyl ethyl ketones, substrate dissolution did not occur, resulting in smaller average tilt angles and arithmetic mean heights of the substrate. It should be noted that while the optical laminate of Comparative Example 2-2 also does not contain monofunctional monomers or highly polar methyl ethyl ketones, it contains a large number of difunctional monomers with a low number of functional groups, thus dissolving the substrate.

[0726] <Examples of optical laminates>

[0727] 5. Measurement and Evaluation

[0728] The optical laminates of the Examples and Comparative Examples were measured and evaluated as follows. It should be noted that the atmosphere for each measurement and evaluation was set to a temperature of 23±5°C and a relative humidity of 40% to 65%. Furthermore, before each measurement and evaluation, the sample was exposed to the above atmosphere for at least 30 minutes. The results are shown in Table 6.

[0729] 5-1. The presence or absence of regions α1 and β1, and the proportion of region α1 present in the second region.

[0730] According to the description in the main text of the specification, samples of the optical laminates of the embodiments and comparative examples with exposed cross sections were prepared. The presence or absence of regions α1 and β1 was confirmed by taking cross-sectional photographs of the samples using a scanning transmission electron microscope. Furthermore, the area ratios of regions α1 and α2, and β1 and β2 were calculated. The presence of a separate region α1 in the first resin layer 21, the resin contained in region α1 being different from that in region α2, and the presence of a separate region β1 in the second resin layer 22, and the resin contained in region β1 being different from that in region β2, can be determined by the brightness difference in the photographs.

[0731] Then, the proportion of regions α existing in the second region is calculated. In calculating the above proportion, multiple cross-sectional photographs are taken until the total number of regions α exceeds 50.

[0732] 5-2. θa1 and θa2, and Pa1 and Pa2

[0733] According to the description in the main text of the specification, samples with exposed cross-sections of the optical laminates of the examples and comparative examples were prepared. Based on cross-sectional photographs of the samples taken using a scanning transmission electron microscope, θa1 and θa2, as well as Pa1 and Pa2, were calculated according to the description in the main text of the specification.

[0734] 5-3. Average thickness of the first and second resin layers

[0735] According to the description in the main text of the specification, samples of the optical laminates of the examples and comparative examples with exposed cross-sections were prepared. Twenty points were selected at any position in the cross-sectional photographs of the above samples taken using a scanning transmission electron microscope, and the average thickness t1 of the first resin layer and the average thickness t2 of the second resin layer were calculated based on their average values.

[0736] 5-4. Total light transmittance (Tt) and haze (Hz)

[0737] The optical laminates of the examples and comparative examples were cut into 10cm square pieces. After visually confirming that there were no abnormalities such as dust or scratches at the cut locations, random locations were selected. Using a haze meter (HM-150, Murakami Color Technology Research Institute), the total light transmittance of each sample according to JIS K7361-1:1997 and the haze according to JIS K7136:2000 were measured.

[0738] It should be noted that, in order to stabilize the light source, after turning on the power switch of the device, wait for more than 15 minutes, and perform calibration without making any settings at the inlet opening (the part where the sample is set). Then, set the sample at the inlet opening and perform the measurement. The light incident surface is the substrate side.

[0739] 5-5. Fit

[0740] The adhesion of the optical laminates of the embodiments and comparative examples was evaluated using the following methods.

[0741] Furthermore, the adhesion of the optical laminates of the Examples and Comparative Examples after the following lightfastness test was evaluated.

[0742] The evaluation samples were cross-cut into a checkerboard pattern of 100 squares (10 vertical and 10 horizontal). The cutting interval was 1 mm. During cutting, the cutter blade entered from the second resin layer side, and the cross-cutting was performed so that the cutter blade reached the top of the substrate.

[0743] Adhesive tape (manufactured by Michelin Co., Ltd., product name "Cellotape" (registered trademark)) was affixed to the surface of the cross-cut samples, and a peel test was performed according to the cross-cut method specified in JIS K 5600-5-6:1999. Based on the results of the peel test, the adhesion was evaluated according to the following evaluation criteria.

[0744] <Evaluation Criteria>

[0745] A: The cross-cut portion that can be identified as being stripped in the grid pattern is less than 5%.

[0746] B: In the grid pattern, the cross-cut portions that can be identified as being stripped are more than 5% but less than 15%.

[0747] C: In the grid pattern, the number of cross-cut sections that can be identified as being stripped is more than 15%.

[0748] <Lightfastness Test>

[0749] Based on JIS B7751, a UV carbon arc lamp type lightfastness and weather resistance tester (manufactured by Suga Testing Equipment Co., Ltd., trade name "FAL-AU·B") was used. The light source was a UV carbon arc lamp, and the irradiance was 500 W / m². 2 Within a black panel temperature of 63°C, the optical laminates of the embodiments and comparative examples were arranged with the resin layer side facing the light source, and a 200-hour test was conducted.

[0750] 5-6. Transmission image sharpness (transmission image sharpness according to JIS K7374:2007)

[0751] The transmitted image sharpness of the optical laminates of the Examples and Comparative Examples was measured. The light incident surface was the substrate side. The measuring apparatus used was an image sharpness measuring instrument (trade name: ICM-1T) manufactured by Suga Testing Machine Co., Ltd. The total transmitted image sharpness for the widths of the four optical combs is shown in Table 6 (in "%)". The widths of the four combs used were 0.125 mm, 0.5 mm, 1.0 mm, and 2.0 mm.

[0752] Furthermore, for the optical laminates of the examples and comparative examples after the above lightfastness test, the transmitted image sharpness was measured in the same manner as described above. The total transmitted image sharpness across the widths of the four optical combs is shown in Table 6 (in "%)".

[0753] The difference in clarity of the transmitted image before and after the lightfastness test is shown in Table 6 (in "%)". A difference of 10.0% or less is considered acceptable, and more preferably, the difference is 5.0% or less.

[0754] 5-7. Anti-glare

[0755] A sample (sample size: 20cm x 30cm) was fabricated by bonding a black plate (KURARAY, Comoglass DFA2CG 502K (Black) series, 0% total light transmittance, 2mm thickness, refractive index 1.49) to the substrate side of the optical laminate of the examples and comparative examples, separated by a 25μm thick transparent adhesive layer (PANAC Corporation, trade name "PANACLEAN PD-S1"). Under bright ambient conditions (illuminance on the first main surface of the sample was between 500 lux and 1000 lux; illumination: Hf32 type straight tube three-wavelength neutral white fluorescent lamp), the sample was viewed from above at a straight-line distance of 50cm from the center of the first main surface. Twenty subjects evaluated the degree of anti-glare performance, based on the following criteria: the level of illumination provided was 2m above a horizontal platform in the vertical direction. The subjects were healthy individuals in their 30s with visual acuity of 0.7 or better.

[0756] A: There were 14 or more people who gave good answers.

[0757] B: 7 to 13 people answered well.

[0758] C: Fewer than 6 people answered well.

[0759] 6. Fabrication of optical laminates

[0760] [Example 3-1]

[0761] (Substrate manufacturing)

[0762] The copolymer of methyl methacrylate and methyl acrylate was compounded at 260°C using a twin-screw extruder to obtain a granular composition (glass transition temperature: 134°C). The resulting granular composition was melt-extruded using a T-die (T-die temperature: 260°C) and discharged onto a cooling roller at 130°C. Subsequently, it was biaxially stretched sequentially in both the longitudinal and transverse directions at a stretch ratio of 1.5 times at a stretching temperature of 145°C. Cooling was then performed to obtain an acrylic resin matrix with a thickness of 40 μm.

[0763] (Formation of the resin layer)

[0764] On the aforementioned acrylic resin substrate, a Mayer rod coating method was used at a rate of 6.0 g / m². 2After applying the coating liquid to the resin layer of Example 3-1 in Table 5, the first stage of drying was performed by drying with hot air at a wind speed of 5 m / s and a temperature of 90°C for 30 seconds. Then, the coating liquid was dried with hot air at a wind speed of 20 m / s and a temperature of 90°C for 30 seconds to perform the second stage of drying. Next, under a nitrogen atmosphere with an oxygen concentration of less than 200 ppm, the cumulative light intensity was 100 mJ / cm². 2 The resin layer coating liquid is irradiated with ultraviolet light, thereby curing the ionizing radiation-curable resin composition to form a first resin layer and a second resin layer, resulting in the optical laminate of Example 3-1. In this specification, coating amount refers to the amount of coating after drying.

[0765] [Examples 3-2 to 3-4], [Comparative Examples 3-1 to 3-3]

[0766] By changing the composition of the coating liquid for the resin layer, the coating amount of the coating liquid for the resin layer, and the drying conditions of the coating liquid for the resin layer to the composition described in Table 5, optical laminates of Examples 3-2 to 3-4 and Comparative Examples 3-1 to 3-3 were obtained in the same manner as in Example 3-1.

[0767]

[0768] In Table 5, the 6-functional urethane acrylate oligomer represents the urethane acrylate oligomer from Mitsubishi Chemical Co., Ltd. (trade name: UV-7600B, weight average molecular weight: 1400), the 2-functional acrylate monomer represents tetraethylene glycol diacrylate, the 3-functional acrylate monomer represents pentaerythritol triacrylate, the monofunctional acrylate monomer represents 4-hydroxybutyl acrylate, and the photopolymerization initiator represents the trade name "Omnirad 184" from IGM Resins BV.

[0769] [Table 6]

[0770] Table 6

[0771]

[0772] The results in Table 6 confirm that the optical laminate of the embodiment can suppress the decrease in adhesion and the change in the clarity of the transmitted image after the lightfastness test.

[0773] On the other hand, the first resin layer of the optical laminate in Comparative Example 3-1 does not have region α1. Therefore, the optical laminate of Comparative Example 3-1 cannot improve the affinity between the first resin layer and the second resin layer, and the adhesion after the lightfastness test is reduced. In Comparative Example 3-1, it is believed that since the coating liquid for the resin layer contains monofunctional monomers, the compatibility is good, making it difficult to form an island structure, and region α1 is not formed.

[0774] The optical laminate of Comparative Example 3-2 has large θa1 and Pa1, failing to meet both conditions 1B and 2B. Therefore, the transmitted image sharpness of the optical laminate of Comparative Example 3-2 fluctuates drastically after the lightfastness test. It is believed that the reason Comparative Example 3-2 fails to meet conditions 1B and 2B is that, due to the long drying time, the movement of resin components between the first and second resin layers becomes more intense, resulting in larger θa2 and Pa2.

[0775] The optical laminate of Comparative Example 3-3 has small θa1 and Pa1, failing to meet both conditions 1B and 2B. Therefore, the optical laminate of Comparative Example 3-3 cannot improve the adhesion after the lightfastness test. It should be noted that the adhesion of the optical laminate of Comparative Example 3-3 before the lightfastness test was also insufficient. The reason why Comparative Example 3-3 fails to meet conditions 1B and 2B is believed to be that the coating liquid used for the resin layer does not contain a difunctional monomer.

[0776] Explanation of reference numerals in the attached figures

[0777] 10: Substrate

[0778] 20A: Resin layer

[0779] 21A: First resin layer

[0780] 22A: Second resin layer

[0781] 23A: Particle 1

[0782] 20B: Resin layer

[0783] 21B: Area 1

[0784] 22B: Area 2

[0785] 23B: Particle 1

[0786] 20C: Resin layer

[0787] 21C: First resin layer

[0788] 22C: Second resin layer

[0789] 100A: Anti-glare laminate

[0790] 100B: Anti-glare laminate

[0791] 100C: Optical laminate

[0792] 200: Display element

[0793] 500: Image display device

Claims

1. An anti-glare laminate, which is an anti-glare laminate having a resin layer on a substrate, wherein, The resin layer has a first resin layer and a second resin layer from the substrate side. The resin layer contains a first particle with an average particle size of 0.5 μm or more. More than 70% of the first particles, based on the number of such particles, are present across the first resin layer and the second resin layer. The anti-glare laminate satisfies the following equation 1. 5.0 < t1 / t2 < 15.0 (Equation 1) In Formula 1, t1 represents the average thickness of the first resin layer, and t2 represents the average thickness of the second resin layer.

2. The anti-glare laminate as described in claim 1, wherein, The average particle size of the first particle, D1, and the average thickness of the second resin layer, t2, satisfy the relationship t2 < D1.

3. The anti-glare laminate as described in claim 1, wherein, The relationship between D1, which represents the average particle size of the first particle, and t1, which represents the average thickness of the first resin layer, satisfies the relationship that D1 < t1.

4. The anti-glare laminate as described in claim 1, wherein, The first particle is an organic particle.

5. The anti-glare laminate as described in claim 1, wherein, The average tilt angle of the surface of the resin layer side of the substrate is more than 5.0 degrees and less than 15.0 degrees.

6. The anti-glare laminate as described in claim 1, wherein, The arithmetic mean height of the surface of the resin layer side of the substrate is more than 0.05 μm and less than 0.25 μm.

7. The anti-glare laminate as described in claim 1, wherein, The hardness of the indentation at the center of the thickness direction of the first resin layer (H1) and the hardness of the indentation at the center of the thickness direction of the second resin layer (H2) satisfy the relationship H1 < H2.

8. The anti-glare laminate as described in claim 7, wherein 40 MPa < H2 - H1.

9. The anti-glare laminate as described in claim 7, wherein 40MPa < H2 - H1 ≤ 100MPa.

10. The anti-glare laminate as claimed in claim 1, wherein, The resin layer comprises a cured product of a curable resin composition.

11. The anti-glare laminate as claimed in claim 1, wherein, The substrate is an acrylic resin substrate.

12. The anti-glare laminate as claimed in claim 1, wherein, The overall thickness of the resin layer is between 7.0 μm and 15.0 μm.

13. The anti-glare laminate as claimed in claim 1, wherein, The average thickness t1 of the first resin layer is more than 5.0 μm and less than 13.0 μm.

14. The anti-glare laminate as claimed in claim 1, wherein, The average thickness t2 of the second resin layer is 0.3 μm or more and 4.0 μm or less.

15. The anti-glare laminate as claimed in claim 1, wherein, JIS K7361-1:1997 states that the total light transmittance is over 70%.

16. The anti-glare laminate as claimed in claim 1, wherein, JIS K7136:2000 specifies a haze level of 0.5% to 20%.

17. An anti-glare laminate, which is an anti-glare laminate having a resin layer on a substrate, wherein, The resin layer contains a first particle with an average particle size of 0.5 μm or more. When the substrate side of the resin layer, extending from its center in the thickness direction, is defined as the first region, and the opposite side of the substrate side of the resin layer, extending from its center in the thickness direction, is defined as the second region, more than 70% of the first particles are present in the second region. The anti-glare laminate satisfies either condition 1A or condition 2A. <Condition 1A> The average tilt angle of the surface of the resin layer side of the substrate is 5.0 degrees or more and 20.0 degrees or less. <Condition 2A> The arithmetic mean height of the surface of the resin layer side of the substrate is 0.10 μm or more and 0.40 μm or less.

18. The anti-glare laminate as claimed in claim 17, wherein, The average particle size D1 of the first particle and the average thickness t of the resin layer satisfy the relationship 2.0 < t / D1 < 6.

0.

19. The anti-glare laminate as claimed in claim 17, wherein, The first particle is an organic particle.

20. The anti-glare laminate as claimed in claim 17, wherein, The resin layer comprises a cured product of a curable resin composition.

21. The anti-glare laminate as claimed in claim 17, wherein, The substrate is an acrylic resin substrate.

22. The anti-glare laminate as claimed in claim 17, wherein, The average thickness of the resin layer is between 6.0 μm and 15.0 μm.

23. The anti-glare laminate as described in claim 17, wherein, The average particle size of the first particle is less than 3.0 μm.

24. The anti-glare laminate as claimed in claim 17, wherein, JIS K7361-1:1997 states that the total light transmittance is over 70%.

25. The anti-glare laminate as claimed in claim 17, wherein, JIS K7136:2000 specifies a haze level of 0.5% to 20%.

26. An optical laminate, wherein an optical laminate has a resin layer on a substrate, wherein, The resin layer has a first resin layer and a second resin layer from the substrate side. The first resin layer has mutually independent regions α1 and regions α2 surrounding regions α1, wherein the resin contained in region α1 is different from the resin contained in region α2. The second resin layer has mutually independent regions β1 and regions β2 surrounding regions β1, wherein the resin contained in region β1 is different from the resin contained in region β2. The optical laminate satisfies either condition 1B or condition 2B. <Condition 1B> The average tilt angle θa1 of the surface representing the resin layer side of the substrate and the average tilt angle θa2 of the surface representing the second resin layer side of the first resin layer satisfy the relationship θa2 < θa1. <Condition 2B> Pa1, which represents the arithmetic mean height of the surface on the resin layer side of the substrate, and Pa2, which represents the arithmetic mean height of the surface on the second resin layer side of the first resin layer, satisfy the relationship Pa2 < Pa1.

27. The optical laminate of claim 26, wherein, The θa1 is between 5.0 degrees and 20.0 degrees.

28. The optical laminate of claim 26, wherein, The θa2 is below 10.0 degrees.

29. The optical laminate of claim 26, wherein, The Pa1 is between 0.05 μm and 0.25 μm.

30. The optical laminate of claim 26, wherein, The Pa2 is below 0.15 μm.

31. The optical laminate of claim 26, wherein, When the substrate side of the first resin layer, starting from the center in the thickness direction, is defined as the first region, and the second resin layer side of the first resin layer, starting from the center in the thickness direction, is defined as the second region, more than 70% of the region α1 exists in the second region.

32. The optical laminate of claim 26, wherein, The resin contained in region α1 is substantially the same as the resin contained in region β2, and the resin contained in region α2 is substantially the same as the resin contained in region β1.

33. The optical laminate of claim 26, wherein, The resin layer contains a first particle with an average particle size of 0.5 μm or more.

34. The optical laminate of claim 33, wherein, The second resin layer contains the first particle.

35. The optical laminate of claim 33, wherein, The first particle is an organic particle.

36. The optical laminate of claim 26, wherein, The substrate is an acrylic resin substrate.

37. The optical laminate of claim 26, wherein, The resin layer comprises a cured product of a curable resin composition.

38. The optical laminate of claim 26, wherein, The overall thickness of the resin layer is between 4.0 μm and 15.0 μm.

39. The optical laminate of claim 26, wherein, The average thickness t1 of the first resin layer is more than 3.0 μm and less than 10.0 μm.

40. The optical laminate of claim 26, wherein, The average thickness t2 of the second resin layer is 0.3 μm or more and 4.0 μm or less.

41. The optical laminate of claim 26, wherein, JIS K7361-1:1997 states that the total light transmittance is over 70%.

42. The optical laminate of claim 26, wherein, JIS K7136:2000 specifies a haze level of 0.5% to 20%.

43. A polarizer comprising a polarizing element, a first transparent protective plate disposed on one side of the polarizing element, and a second transparent protective plate disposed on the other side of the polarizing element, wherein, At least one of the first transparent protective plate and the second transparent protective plate is selected from any one of the anti-glare laminates of claim 1, the anti-glare laminates of claim 17, and the optical laminates of claim 26.

44. An image display device having on a display element any one selected from the anti-glare laminate of claim 1, the anti-glare laminate of claim 17, and the optical laminate of claim 26.

45. The image display apparatus as claimed in claim 44, wherein, The image display device is a foldable image display device or a rollable image display device, and the display element has the anti-glare laminate as described in claim 1 or the anti-glare laminate as described in claim 17.

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