Laminated film and method for manufacturing laminated film

Abstract

The present invention provides a laminate film capable of inhibiting excessive deformation of a pattern shape of ink. The laminate film of an embodiment of the present invention successively includes an adhesive layer, a resin layer, and a release liner. The resin layer includes resin portions arranged separately from each other on the adhesive layer. An equivalent diameter of the resin portions is 150 μm or less.

Description

Technical Field

[0001] This invention relates to laminated films and methods for manufacturing laminated films. Background Technology

[0002] It is known that light reflection efficiency can be improved by depositing a low-refractive-index layer with a porous structure on a substrate, thereby increasing and maintaining the intensity of emitted light in optical components such as lighting devices that include a light source and a light guide layer. Furthermore, optical components capable of distributing light have been fabricated by partially depositing a low-refractive-index layer on a substrate to change the light exit position. Using such an optical component allows for efficient distribution of light incident on the light guide layer, enabling the realization of an optical component capable of extracting the desired light.

[0003] For example, in order to partially configure a low refractive index layer, a technique has been proposed to fabricate a laminated film having a pattern formed by ink, and to transfer the pattern of the ink onto a coated film of a laminated body on a substrate to which a material forming a low refractive index layer is coated (e.g., Patent Document 1).

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: International Publication No. 2019 / 182100 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, if the aforementioned laminated film is wound into a roll and stored, the shape of the ink pattern may sometimes change significantly.

[0009] The purpose of this invention is to provide a laminated film capable of suppressing excessive shape changes in ink patterns and a method for manufacturing the same.

[0010] Problem Solving Methods

[0011] [1] The laminated film of the embodiment of the present invention sequentially comprises an adhesive layer, a resin layer, and a release liner. The resin layer includes resin portions disposed separately from each other on the adhesive layer. The equivalent diameter of the resin portions is 150 μm or less.

[0012] [2] In the laminated film described in [1] above, the resin portion may contain at least one selected from the dried product, semi-cured product and cured product of the resin composition.

[0013] [3] In the laminated film described in [2] above, the resin composition may contain a photocurable resin.

[0014] [4] In the laminated film described in [3] above, the photocurable resin may contain at least one resin selected from urethane (meth) acrylate, epoxy (meth) acrylate and polyester (meth) acrylate.

[0015] [5] In any of the above-mentioned [1] to [4] laminated films, when measured according to ISO 14577 by pressing the indenter into 2000 nm using a nanoindenter, the nanoindentation hardness of the adhesive layer can be 0.5 MPa or more.

[0016] [6] In any of the above-mentioned [1] to [5] laminated films, the ratio of the area of ​​the resin portion to the total area of ​​the adhesive layer may be 60% or less.

[0017] [7] A method for manufacturing a laminated film according to other aspects of the present invention includes: disposing resin portions constituting resin layers separately on the adhesive layer on the laminate having a support member and an adhesive layer; and disposing a release liner covering the laminate and the resin portions.

[0018] [8] The method for manufacturing the laminated film described in [7] above may include heating the resin portion after it has been disposed.

[0019] [9] The method of manufacturing the laminated film described in [7] or [8] above may include winding it into a roll after the release liner is configured.

[0020] The effects of the invention

[0021] According to embodiments of the present invention, a laminated film capable of suppressing excessive shape changes in the pattern of ink can be obtained. Attached Figure Description

[0022] Figure 1A This is a cross-sectional schematic diagram of a laminated film according to one embodiment of the present invention.

[0023] Figure 1B It is perspective observation Figure 1A A top view diagram obtained by peeling off the laminated film.

[0024] Figure 2 This is a perspective view illustrating an example of a laminated film formed into a roll shape according to one embodiment of the present invention.

[0025] Figure 3 This is a cross-sectional schematic diagram illustrating an example of peeling a release liner from a laminated film according to one embodiment of the present invention.

[0026] Figure 4A This is a cross-sectional schematic diagram of an optical component according to one embodiment of the present invention.

[0027] Figure 4B This is a cross-sectional schematic diagram of an optical component according to another embodiment of the present invention.

[0028] Figure 5 This is a cross-sectional schematic diagram illustrating an example of a process in manufacturing an optical component according to an embodiment of the present invention.

[0029] Symbol Explanation

[0030] 10 Adhesive Layer

[0031] 20 resin layers

[0032] 21 Resin Section

[0033] 30 Peeling Liner

[0034] 40 Supporting components (stripping liner)

[0035] 50 Substrate

[0036] 60 Low Refractive Index Layer

[0037] 100-layer film Detailed Implementation

[0038] The following describes representative embodiments of the present invention, but the present invention is not limited to these embodiments. It should be noted that, for ease of observation and understanding, the accompanying drawings are schematic or conceptual, and the length, width, shape, size, ratio, direction, number, etc., may sometimes differ from the actual figures, resulting in non-correspondence between the drawings.

[0039] In this specification, "A and / or B" means any of the meanings of "A", "B", or "A and B". Additionally, in this specification, "(meth)acrylic acid" means "methacrylic acid" and / or "acrylic acid". For example, "(meth)acrylate" means "methacrylate" and / or "acrylate".

[0040] A. Overall composition of laminated films

[0041] Figure 1A This is a cross-sectional schematic diagram of a laminated film according to one embodiment of the present invention.

[0042] The laminated film 100 shown in the figure sequentially comprises an adhesive layer 10, a resin layer 20, and a release liner 30. The resin layer 20 includes resin portions 21 disposed separately from each other on the adhesive layer 10. The equivalent diameter of the resin portions 21 is 150 μm or less.

[0043] Typically, for laminated films, a long strip of laminated film formed by overlapping multiple films is wound into a roll with a release liner sandwiched between two or one side of the outermost layer of the laminate, and stored in a roll. Furthermore, the laminated film can be unloaded from the roll at any appropriate time and used for various purposes.

[0044] In addition, ink is sometimes used to form a given pattern shape on the laminated film. However, as mentioned above, since the laminated film is wound into a roll and stored in a roll, the shape of the ink pattern in the laminated film can sometimes change significantly before and after storage. Specifically, sometimes the desired pattern shape cannot be maintained due to ink deformation, such as excessive expansion in the planar direction of the ink surface and / or bulging or depression in the thickness direction.

[0045] Therefore, the inventors conducted extensive research to provide a laminated film that can suppress excessive shape changes in the ink pattern even when stored in rolls. As a result, the laminated film according to the embodiments of the present invention was completed.

[0046] That is, the laminated film of the embodiments of the present invention sequentially comprises an adhesive layer, a resin layer, and a release liner. The resin layer includes resin portions disposed separately from each other on the adhesive layer. The equivalent diameter of the resin portions is 150 μm or less. By having such a configuration, the laminated film of the embodiments of the present invention can suppress excessive deformation of the ink (which is essentially the resin portion constituting the resin layer) even when wound into a roll and stored in a roll. Therefore, in the laminated film of the embodiments of the present invention, excessive shape changes in the ink pattern can be suppressed. The reason why excessive shape changes in the ink pattern can be suppressed in the laminated film of the embodiments of the present invention is not yet clear, but the mechanism described below is conjectured.

[0047] In the laminated film of the embodiments of the present invention, the ink (resin portion) has a relatively small diameter, thereby reducing the contact area between the resin portion, which is separately disposed on the adhesive layer, and each of the adhesive layer and release liner. This suppresses deformation caused by the surface tension between each resin portion and each of the adhesive layer and release liner. As a result, ink deformation is less likely to occur, and therefore excessive shape changes in the ink pattern are considered to be suppressed. It should be noted that such a mechanism is ultimately only speculative and does not limit or restrict the present invention.

[0048] The laminated film of the present invention, by suppressing excessive shape changes in the pattern of the ink (resin portion) as described above, is suitable for imparting a desired pattern shape by transferring it to a transfer substrate. For example, the laminated film of the present invention is suitable for manufacturing optical components with patterned shapes. Furthermore, if the above-described laminated film is used in the manufacture of optical components, a desired pattern shape can be imparted to the optical components, and product defects of the optical components can be suppressed. In addition, since the deformation of the resin portion in the above-described laminated film is suppressed, interference between the resin portions during transfer can also be suppressed, which helps to reduce product defects when manufacturing optical components.

[0049] In this specification, "ink" refers to a liquid or paste-like substance of resin material and / or a resin composition containing resin material.

[0050] In the embodiments of the present invention, the equivalent diameter of the resin portion in the laminated film is 150 μm or less. As described above, by making the equivalent diameter 150 μm or less, it is helpful to suppress excessive shape changes in the pattern of the ink (resin portion). Furthermore, since excessive deformation of the resin portion is less likely to occur, it is also helpful to utilize the formation of fine patterns in the ink (resin portion). "Equivalent diameter of the resin portion" refers to the diameter of the circle assuming the shape of the resin portion is circular when viewed from above. For example, the resin portion of a laminated film with a thickness of 90 μm can be observed using a laser microscope under conditions of 25°C and 0.40 MPa for 13 hours, and the equivalent diameter of the resin portion can be calculated based on the image obtained by image processing. A more specific measurement method is shown in "(2) Ink height, ink diameter and ink shape change rate after pressure" of the embodiment described later. It should be noted that the above conditions are only used to confirm the equivalent diameter and are not intended to limit the measurement of the equivalent diameter under conditions other than those described above. For example, the diameter of the resin portion in the laminated film before pressure can also be measured.

[0051] In embodiments of the present invention, the equivalent diameter of the resin portion in the laminated film is preferably 145 μm or less, more preferably 110 μm or less, further preferably 80 μm or less, particularly preferably 70 μm or less, and especially preferably 65 μm or less. On the other hand, the lower limit of the above-mentioned equivalent diameter of the resin portion is not particularly limited, for example, it is 5 μm or more. Within this range, the laminated film of the embodiments of the present invention exhibits excellent pressure resistance, which, as a result, helps to suppress shape changes in the ink pattern. Within this range, the ink (resin portion) has a relatively small diameter, therefore it can be considered that by winding it into, for example, a roll, even when pressure is applied in the thickness direction of the laminated film, the resin portion will not deform significantly, and its shape is more easily maintained.

[0052] In the laminated film of the embodiment of the present invention, when the above-mentioned laminated film with a thickness of 90 μm is pressurized for 13 hours at a temperature of 25°C and a pressure of 0.40 MPa, the equivalent diameter of the resin portion is preferably 2.5 times or less, more preferably 2.35 times or less, further preferably 2.15 times or less, and particularly preferably 2.0 times or less, of the equivalent diameter before pressurization. If it is within this range, the pressure resistance of the resin portion is particularly excellent. As a result, the shape change of the ink (resin portion) of the laminated film of the embodiment of the present invention can be particularly suppressed. The equivalent diameter of the resin portion after pressurization can be, for example, 1.0 times or more of the equivalent diameter before pressurization. It should be noted that the specific method for measuring the equivalent diameter before pressurization is, for example, based on the method of "(1) height and diameter of ink before pressurization" in the embodiment described later.

[0053] In the laminated film of the embodiments of the present invention, the ratio of the area of ​​the resin portion to the total area of ​​the adhesive layer is preferably 60% or less, more preferably 55% or less, and even more preferably 50% or less. The ratio of the area of ​​the resin portion to the total area of ​​the adhesive layer is, for example, 1% or more. If it is within such a range, even if the laminated film of the embodiments of the present invention is made into a roll, excessive changes in the shape of the ink pattern can be particularly suppressed. "Area of ​​the resin portion" refers to the total area of ​​the separated individual resin portions. The areas of the adhesive layer and the resin portions, as described above, can be observed using a laser microscope and calculated based on an image obtained through image processing.

[0054] As described above, the resin layer 20 comprises a plurality of resin portions 21. These resin portions are disposed separately from each other on the adhesive layer. In other words, the resin portions constitute the resin layer. By dispersing the resin portions from each other on the adhesive layer, it is possible to help suppress excessive changes in the shape of the ink pattern. Therefore, it is possible to further improve the light extraction efficiency of optical components that can be fabricated using the laminated films according to embodiments of the present invention.

[0055] The resin component is preferably disposed directly on the adhesive layer. "Directly disposed" means that the resin component is disposed in contact with the adhesive layer.

[0056] In embodiments of the present invention, the longitudinal and width distances between adjacent resin portions in the laminated film are each preferably 5 μm or more, more preferably 10 μm or more. Conversely, the longitudinal and width distances between the adjacent resin portions are each preferably 300 μm or less, more preferably 250 μm or less, and even more preferably 100 μm or less. If the longitudinal and width distances between adjacent resin portions are within the above ranges, the shape of the pattern of the resin layer (ink) in the laminated film of the present invention can be made finer. The longitudinal and width distances refer to the distance between the centers (centroids) of adjacent resin portions.

[0057] In one embodiment of the laminated film, the shape of the resin portions (ink) pattern is preferably configured such that the resin portions are substantially equally spaced when viewed from above, and more preferably configured such that the resin portions are substantially equally spaced and in a grid pattern when viewed from above. In other words, it is more preferable that the resin portions are arranged substantially equally spaced along the length and width directions on the adhesive layer. In addition, in this case, the respective length direction spacing and width direction spacing are substantially equal to each other. "Substantially equally spaced" is not limited to strictly identical spacing, and a range of ±5 μm is allowed as substantially equally spaced. The same applies to "substantially equal".

[0058] In one embodiment of the invention, the laminated film may substantially have a support member on the side of the adhesive layer opposite to the release liner. See the example figure (see figure). Figure 1A In the laminated film 100, a support member 40, an adhesive layer 10, a resin layer 20, and a release liner 30 are sequentially provided. The support member 40, for example, supports the adhesive layer 10. However, it should be noted that the support member 40 is not a necessary component in the laminated film of the embodiments of the present invention.

[0059] For the laminated film of the embodiments of the present invention, it can be typically illustrated as shown in the figure (e.g.) Figure 2 The long, multi-layered film is wound into a roll and stored in that manner. It should be noted that... Figure 2 In this manner, the release liner 30 is wound so that it is on the inside. However, this is not a limitation; for example, the opposite side of the release liner 30 (in...) can also be wound so that it is on the inside. Figure 2 The middle part (40 sides) is wound in a way that makes the inner side the supporting member.

[0060] B. Details of the laminated membrane

[0061] Next, the constituent elements of the laminated film according to embodiments of the present invention will be specifically described.

[0062] B-1. Adhesive layer

[0063] For example, when fabricating an optical component having a low-refractive-index layer with voids, an adhesive layer can be used adjacent to the main surface of the low-refractive-index layer. Specifically, the adhesive layer is bonded to the low-refractive-index layer. When bonded to the low-refractive-index layer, the adhesive layer preferably has a hardness such that the adhesive constituting the adhesive layer does not penetrate into the voids of the low-refractive-index layer under normal conditions. The storage modulus of the adhesive layer at 23°C is, for example, 1.0 × 10⁻⁶. 5 (Pa) ~1.0×10 7 (Pa), preferably 1.3 × 10 5 (Pa) ~1.0×10 6 (Pa), more preferably 1.5×10 5 (Pa) ~5.0×10 5 (Pa). By setting the storage modulus of the adhesive layer adjacent to the low-refractive-index layer to the range described above, it is possible to prevent the adhesive constituting the adhesive layer from entering the voids of the low-refractive-index layer. Therefore, the refractive index of the low-refractive-index layer can be kept at a low level to maintain its effect. The storage modulus can be determined by reading the value at 23°C at a frequency of 1 Hz, within the range of -50°C to 150°C, at a heating rate of 5°C / min, according to the method described in JIS K 7244-1 "Plastics - Test methods for dynamic mechanical properties".

[0064] Furthermore, the nanoindentation hardness of the adhesive layer is preferably 0.50 MPa or more, more preferably 0.60 MPa or more, and even more preferably 0.65 MPa or more. On the other hand, the nanoindentation hardness of the adhesive layer can be, for example, 2.00 MPa or less. The nanoindentation hardness of the adhesive layer is measured according to ISO 14577. Specifically, the nanoindentation hardness can be obtained by placing the component (e.g., a component having an adhesive layer) in a nanoindenter and pressing the indenter into the nanoindenter at 2000 nm. As a nanoindenter, for example, an apparatus manufactured by Oxford Instruments (model "MFP-3D-SA") can be used, and the nanoindentation hardness can be measured, for example, by the AFM force curve method.

[0065] As the adhesive constituting the adhesive layer, any suitable adhesive can be used as long as it possesses the properties described above. Acrylic adhesives (acrylic adhesive compositions) are representative examples of adhesives. Acrylic adhesive compositions typically contain a (meth)acrylic polymer as the main component (base polymer).

[0066] The weight-average molecular weight (Mw) of (meth)acrylic acid polymers is, for example, 100,000 to 5,000,000, preferably 200,000 to 4,000,000. The weight-average molecular weight (Mw) can be calculated, for example, from the results of GPC determination and by conversion to styrene.

[0067] (Meth)acrylic polymers may be included in the adhesive composition at a proportion of, for example, 50% by weight or more, preferably 70% by weight or more, and more preferably 90% by weight or more of the solid components of the adhesive composition. The (meth)acrylic polymer contains alkyl (meth)acrylates as monomer units as a main component.

[0068] Alkyl groups, such as those having 1 to 18 carbon atoms, can be straight-chain or branched. The average number of carbon atoms in the alkyl group is preferably 3 to 9. Monomers constituting (meth)acrylate polymers, in addition to alkyl methacrylates, can include carboxyl-containing monomers, hydroxyl-containing monomers, amide-containing monomers, aromatic (meth)acrylates, heterocyclic (meth)acrylates, and other comonomers. The comonomers are preferably hydroxyl-containing monomers and / or heterocyclic (meth)acrylates, more preferably N-acryloylmorpholine.

[0069] Acrylic adhesive compositions may preferably contain silane coupling agents and / or crosslinking agents. Examples of silane coupling agents include epoxy-containing silane coupling agents. Examples of crosslinking agents include isocyanate crosslinking agents and peroxide crosslinking agents.

[0070] Details of such adhesive layers or acrylic adhesive compositions are described, for example, in Japanese Patent No. 4140736, which is incorporated herein by reference.

[0071] The thickness of the adhesive layer is preferably 3 μm or more, more preferably 5 μm or more. On the other hand, the thickness of the adhesive layer is preferably 30 μm or less, more preferably 15 μm or less. If the thickness of the adhesive layer is within such a range, it has the advantage of having sufficient adhesion and minimal impact of the adhesive layer thickness on the overall thickness.

[0072] B-2. Stripping Liner

[0073] Typically, the release liner 30 is temporarily adhered to the adhesive layer of the laminated film according to an embodiment of the invention until the adhesive layer is adhered to the object to be bonded, and is peeled off from the adhesive layer 10 when the laminated film is ready for use (see reference). Figure 3 In the example diagram (e.g.) Figure 1B In the laminated film 100, the release liner 30 is temporarily attached to the adhesive layer 10 (the position where the resin part 20 is not configured) and the resin part 20.

[0074] The release liner 30 is formed from any suitable resin film that can be used as a release liner. Specific examples of materials that are the main components of the resin film include polyethylene terephthalate (PET), polyethylene, and polypropylene. The resin film material can be used alone or in combination. The release liner 30 can be transparent or opaque.

[0075] The release liner 30 can be a resin film whose main surface has undergone a release treatment on one or both sides. Specifically, a release treatment layer can be provided on the main surface of one or both sides of the release liner 30. Examples of release agents forming the release treatment layer include silicone-based release agents, fluorinated release agents, and long-chain alkyl acrylate release agents; silicone-based release agents are preferred, and vinyl-containing addition-type silicones are even more preferred. The release agent can be used alone or in combination. The thickness of the release treatment layer is typically 50 nm or more and 400 nm or less.

[0076] The thickness of the release liner 30 is typically 5 μm or more, preferably 20 μm or more, and typically 60 μm or less, preferably 45 μm or less. It should be noted that when a release treatment layer is applied, the thickness of the release liner includes the thickness of the release treatment layer.

[0077] B-3. ​​Resin layer

[0078] The resin layer in the laminated film of embodiments of the present invention comprises a resin portion separately disposed on an adhesive layer. The resin portion may be formed from a resin composition (ink). More specifically, the resin portion comprises a liquid or paste-like ink formed by applying a resin composition onto the adhesive layer. The resin portion preferably comprises a dried, semi-cured, and cured portion of the resin composition.

[0079] The resin composition typically contains a resin material, and additives and / or solvents as needed. Any suitable resin material can be used depending on the purpose. The resin material may include, for example, an active energy ray-curable resin. Examples of active energy ray-curable resins include photocurable resins. That is, the resin composition preferably contains a photocurable resin. If the resin composition contains a photocurable resin, the time point for curing the resin composition can be easily controlled. For example, when applying the laminate of the present invention to a low-refractive-index layer having a porous layer to impart a patterned shape of ink in the laminate to the low-refractive-index layer, it can be cured by light irradiation after transferring the ink formed by the resin composition. As a result, optical components with highly refined ink patterned shapes can be produced with good efficiency.

[0080] Photocurable resins are typically ultraviolet (UV)-curable resins. Specific examples of UV-curable resins include (meth)acrylic acid resins, urethane resins, amide resins, silicone resins, epoxy resins, and polyester resins. It should be noted that these resins can contain photocurable monomers, oligomers, and polymers. The selected resins can be used alone or in combination.

[0081] The (meth)acrylate resin preferably contains monomeric components and / or oligomer components having two or more, more preferably three to six polymerizable functional groups. Specific examples of acrylic resins include epoxy (meth)acrylates, polyester (meth)acrylates, (meth)acrylates, ether (meth)acrylates, etc. The photocurable resin preferably contains at least one resin selected from urethane (meth)acrylates, epoxy (meth)acrylates, and polyester (meth)acrylates. By containing such a resin as the photocurable resin, it is easier to control the curing time of the resin composition, thus enabling the production of optical components with highly precise ink patterns with greater efficiency. Among these, the photocurable resin particularly preferably contains urethane (meth)acrylates.

[0082] The resin composition may contain any suitable additives depending on the type, formulation, and composition of the resin material. For example, when the resin composition contains a photocurable resin, it preferably contains a photopolymerization initiator. When curing the photocurable resin, any suitable curing method may be used depending on the resin's composition, structure, etc. Curing methods include, for example, free radical polymerization and cationic polymerization.

[0083] Preferably, the thickness of the resin layer is less than the thickness of the release liner. With this configuration, the outermost layer of the laminated film according to embodiments of the present invention can be made flat. As a result, the pressure applied to the interior when the laminated film is rolled into a roll can be further reduced. It should be noted that the "thickness of the resin layer" mentioned here refers to the thickness of the resin layer (ink) before pressure is applied. Furthermore, the thickness of the resin layer is calculated as the arithmetic mean of the thicknesses of the resin portions before pressure at three randomly selected locations.

[0084] The thickness of the resin layer before pressure application is preferably 1.5 μm or more and 5.6 μm or less, and the equivalent diameter of the resin portion before pressure application is 15 μm or more and 42 μm or less. More preferably, the thickness of the resin layer before pressure application is 1.5 μm or more and 3.3 μm or less. Within this range, the pressure resistance of the laminated film according to the embodiments of the present invention is particularly excellent. As a result, shape changes in the coating of the laminated film according to the embodiments of the present invention can be particularly suppressed. The specific method for measuring the thickness of the resin layer before pressure application is as described above, based on the method of "(1) Ink height and ink diameter before pressure application" in the following examples. The same applies to the equivalent diameter of the resin portion before pressure application.

[0085] B-4. Other components

[0086] In a laminated film according to one embodiment of the present invention, a support member is provided on the side of the adhesive layer opposite to the resin layer. As described above, the support member supports the adhesive layer, for example. For example, as shown in the illustrated example (…). Figure 1A As in the example, the laminated film 100 sequentially comprises a support member 40, an adhesive layer 10, a resin layer 20, and a release liner 30. The support member 40, for example, supports the adhesive layer 10 in the laminated film 100 according to one embodiment of the present invention. With the support member present, when the laminated film of the embodiment of the present invention is wound into a roll, the support member is sandwiched between the support member, thereby preventing the release liner (the outermost layer of the laminated film) from overlapping with the adhesive layer. As a result, the laminated film can be easily unwound from the roll. Furthermore, the adhesive layer can be protected until it is supplied to the optical component, thus maintaining adhesion for a longer period.

[0087] The support member 40 may be, for example, any suitable resin film. The resin film may contain the same material as the resin film constituting the release liner described in section B-2 above, which is a main component.

[0088] The support member 40 can also be a release liner. That is, the surface of the resin film of the support member can be subjected to a release treatment. The support member can be the same as or different from the release liner described above (for convenience, the release liner in item B-2 is referred to as the first release liner). When the support member 40 is a release liner (for convenience, it is referred to as the second release liner), it can be easily used when optical components are made from the laminated film of the embodiment of the present invention and when the optical components are applied to other components (e.g., light guide plates, etc.).

[0089] The support member can have any suitable thickness. For example, the thickness of the support member is 5 μm or more and 100 μm or less. Preferably, the thickness of the support member is 10 μm or more.

[0090] B-5. Manufacturing method of laminated films

[0091] The laminated film of embodiments of the present invention can be manufactured, for example, by forming a resin layer by disposing a resin portion on an adhesive layer disposed on a support member, and by disposing a release liner covering the resin layer and the adhesive layer. More specifically, the laminated film of embodiments of the present invention can be manufactured, for example, as described below.

[0092] First, prepare the support components, adhesive layer, release liner, and resin composition.

[0093] Regarding the adhesive layer, any suitable adhesive (adhesive composition) constituting the adhesive layer can be applied to form the support member, or an adhesive layer formed on another support member can be transferred. Sometimes the laminate of the support member and the adhesive layer is referred to as the first laminate (first laminate 110 in the example).

[0094] A resin composition is applied to the adhesive layer of the first laminate. By applying the resin composition, resin portions are disposed separately from each other. The resin portions can be manufactured by forming a film of the resin composition using any suitable coating method. Examples of coating methods include spraying, roller coating, spin coating, etc.; and printing methods such as inkjet printing, screen printing, etc. Any suitable coating apparatus can be used for coating. Specific examples of coating apparatus include: spray coating machines, roller coating machines, spin coating machines, dispensing machines, inkjet coating machines (inkjet printers), screen printers, etc.

[0095] As an example, the following describes coating using inkjet printing.

[0096] A resin composition (ink) is injected into the injection port of the inkjet device. Additionally, a first laminate is arranged below the nozzle of the inkjet device such that the adhesive layer faces the nozzle side.

[0097] Next, the resin composition is ejected from the nozzle of the inkjet device. In inkjet printing, the spacing is adjusted to allow for easy ejection of the resin composition. Therefore, by using an inkjet device, the resin portion can be easily positioned off the ground. As a result, the resin layer can be formed with a suitable pattern shape created by the ink.

[0098] Thus, a resin layer is formed on the adhesive layer. The resin portion on the adhesive layer can be arranged, for example, by spraying while the first laminate is being rolled. As a result, a pattern formed by the resin portion (ink) can be formed on the resin layer.

[0099] The shape of each resin portion in the resin layer, viewed from above, can be set to any suitable shape. That is, the shape of the resin portion in view from above can be adjusted to any suitable shape according to the settings of the inkjet device, the type, composition, and composition ratio of the resin material, additives, and solvents in the resin composition, as well as the physical properties such as the viscosity of the resin composition. Examples of resin portion shapes that appear circular, elliptical, rectangular, or polygonal in view from above are possible. The resin portions only need to be separated from each other in view from above, and the shape of the resin portions in view from above can also be formed as a strip (also called a line).

[0100] Next, a release liner is disposed on the adhesive layer where the resin portion is disposed (or a first release liner if the support member is a second release liner). The release liner may be disposed overlappingly on the resin portion and the side of the adhesive layer where the resin portion is not disposed. Thus, the release liner can cover both the resin portion and the adhesive layer.

[0101] Therefore, the laminated film of the embodiments of the present invention can be produced.

[0102] In one embodiment, the resin composition can be dried under any suitable conditions after the resin portion (resin composition) is disposed on the adhesive layer. When drying the resin composition, it is preferable to heat the resin portion disposed on the adhesive layer. Thus, the resin layer can consist of a dried, semi-cured, or cured form of the resin composition. That is, the resin layer contains at least one of a dried, semi-cured, or cured form of the resin composition. The heating temperature is, for example, 80°C or higher and 150°C or lower, and the drying time is, for example, 1 minute or more and 1 hour or less. However, the drying conditions are not limited to the above conditions; for example, it can be dried by leaving it at room temperature for any amount of time without heating. Furthermore, the drying of the resin portion can be performed before or after the release liner is disposed.

[0103] In this way, the laminated film of the embodiments of the present invention can be produced.

[0104] In another embodiment, the process may include winding the film into a roll after the release liner is applied to the resin portion and the adhesive layer. Therefore, the laminated film of the embodiments of the present invention can be in a roll shape. If the laminated film is wound into a roll, the pressure applied is generally greater towards the inside of the roll, making the resulting ink (resin portion) more prone to deformation. In contrast, the laminated film of the embodiments of the present invention has the advantage of suppressing excessive deformation of the resin portion and suppressing excessive shape changes in the pattern shape of the ink, even when wound into a roll.

[0105] In this way, the laminated film of the embodiments of the present invention can be produced.

[0106] However, it should be noted that the manufacturing method of the laminated film in the embodiments of the present invention is not limited to the above-described method and sequence, and may include any appropriate steps within the limits that do not impair the effect of the present invention.

[0107] C. Optical components

[0108] C-1. Overall Structure of Optical Components

[0109] The laminated film in embodiments of the present invention can, for example, be a component of an optical element. Therefore, embodiments of the present invention also include such an optical element. Hereinafter, such an optical element will be described.

[0110] Figure 4A This is a cross-sectional schematic diagram of an optical component according to one embodiment of the present invention.

[0111] The optical component 200 shown in the figure sequentially comprises a substrate 50, a low refractive index layer 60, an adhesive layer 10, and a release liner 40. Resin portions 21 are disposed separately from each other on the low refractive index layer 60. The equivalent diameter of the resin portions 21 is 150 μm or less. Due to this configuration, the optical component according to the embodiment of the present invention can suppress excessive changes in the pattern shape of the ink and can have a good pattern shape.

[0112] The optical component of the embodiments of the present invention can typically have a light distribution function. The light distribution function refers to, for example, the following: by distributing a laminated film on a light guide layer, a portion of the light from the light source is partially blocked from escaping from one side of the light guide layer by total internal reflection using a low-refractive-index layer. This ensures that a portion of the light is emitted from the part of the light guide layer where the low-refractive-index layer is not located, thereby adjusting the light intensity. This allows the light output to change according to the position of the light guide layer relative to the light source. If light distribution can be achieved, it can help to make the brightness of the light emitted from the light guide layer more uniform. In the optical component of the embodiments of the present invention, as described above, since excessive shape changes of the ink (the resin portion in the resin layer) can be suppressed, it is easy to impart the ink pattern shape to the low-refractive-index layer, and the pattern shape can be miniaturized.

[0113] Furthermore, the optical component according to embodiments of the present invention can also suppress defects in pattern shape. Additionally, since the optical component according to embodiments of the present invention can also effectively achieve miniaturization of the low-refractive-index layer, it can achieve very high-efficiency light distribution.

[0114] Hereinafter, the constituent elements of the optical component according to the embodiments of the present invention will be specifically described.

[0115] As described above, the optical components of the embodiments of the present invention can use the laminated films of the embodiments described in items A and B (B-1 to B-5) above. Therefore, regarding the common configurations in the optical components of the embodiments of the present invention that are common to the laminated films described above, the descriptions of the laminated films are referenced, and appropriate descriptions are omitted.

[0116] C-2. Substrate

[0117] The substrate supports, for example, a low-refractive-index layer in the optical component. The substrate can have the same configuration as the support member in the laminated film described above. Therefore, regarding the substrate, the description of the support member in section B-4 of the laminated film described above can be referenced.

[0118] As the substrate, any suitable resin film other than the supporting member described in section B-4 above can be used. For example, the resin film can typically be composed of a film or plate of resin (preferably a transparent resin). Representative examples of such resins include thermoplastic resins and reactive resins (e.g., ionizing radiation-curing resins). Specific examples of thermoplastic resins include polymethyl methacrylate (PMMA), (meth)acrylic resins such as polyacrylonitrile, polycarbonate (PC) resins, polyester resins such as PET, cellulose resins such as cellulose triacetate (TAC), cyclic polyolefin resins, and styrene resins. Specific examples of ionizing radiation-curing resins include epoxy acrylate resins and urethane acrylate resins. These resins can be used alone or in combination of two or more.

[0119] The refractive index of the substrate is preferably 1.47 or higher, more preferably 1.47 to 1.60, and even more preferably 1.47 to 1.55. If it is within such a range, when the optical component of the embodiment of the present invention is applied to the light guide layer (light guide component), the brightness and uniformity of the light emitted from the light guide layer can be improved.

[0120] The substrate can have any suitable thickness. For example, the thickness of the substrate is greater than 1 μm and less than 100 μm.

[0121] C-3. Low refractive index layer

[0122] Low refractive index layers, for example, have the function of reflecting light from a light source with good efficiency within the light guide layer when optical components are applied to light guide plates, etc.

[0123] The refractive index of the low-refractive-index layer is, for example, lower than that of the substrate. The refractive index of the low-refractive-index layer is, for example, 1.30 or less, with a lower limit exceeding 1.00. The refractive index of the low-refractive-index layer is preferably 1.13 to 1.28, more preferably 1.14 to 1.27, further preferably 1.15 to 1.26, and particularly preferably 1.16 to 1.25. If the refractive index of the low-refractive-index layer is within such a range, it is possible to fabricate an optical component with a patterned low-refractive-index layer disposed on a substrate, which can perform light distribution functions particularly well. It should be noted that, unless otherwise specified, the refractive index refers to the refractive index measured at a wavelength of 550 nm. For example, the refractive index can be measured using an ellipsometer (JAWoollam Japan: VASE) with a wavelength of 550 nm and an incident angle of 50 to 80 degrees.

[0124] The total light transmittance of the low-refractive-index layer is preferably 85% to 99%, more preferably 87% to 98%, and even more preferably 89% to 97%. By providing such a low-refractive-index layer on the first main surface of the substrate, for example, excellent transparency can be achieved throughout the laminate. As a result, visual legibility can be ensured, for example, when the laminate is applied to various products. The total light transmittance can be measured, for example, using a haze meter (e.g., the "HM-150" manufactured by Murakami Color Technology Research Institute Co., Ltd.).

[0125] The haze of the low-refractive-index layer is preferably less than 5%, more preferably less than 3%. On the other hand, the haze is, for example, 0.1% or more, and can be 0.2% or more. By providing such a low-refractive-index layer on the first main surface side of the substrate, excellent transparency can be achieved, for example, throughout the laminated film. The haze can be calculated, for example, using the same value measured by a haze meter as described above, and by the following formula.

[0126] Haze (%) = [Diffuse transmittance (%) / Total light transmittance (%)] × 100 (%)

[0127] The thickness of the low-refractive-index layer is, for example, 0.1 μm or more, preferably 0.3 μm or more, more preferably 1.0 μm or more, further preferably 1.2 μm or more, particularly preferably 1.5 μm or more, and especially preferably 1.8 μm or more. Alternatively, the thickness of the low-refractive-index layer can be, for example, 2.2 μm or more, or for example, 2.5 μm or more, or for example, 2.8 μm or more. On the other hand, the thickness of the low-refractive-index layer can be, for example, 20 μm or less, or for example, 10 μm or less, or for example, 8 μm or less, or for example, 5 μm or less. If the thickness of the low-refractive-index layer is within such a range, the optical component of the embodiments of the present invention can perform its light distribution function and light intensity adjustment function particularly well.

[0128] The low-refractive-index layer has a porous structure. The low-refractive-index layer can be constructed using any suitable configuration that achieves the aforementioned desired properties. The material used to form the low-refractive-index layer (hereinafter sometimes referred to as "material for forming a low-refractive-index layer") can be, for example, the materials described in International Publication No. 2004 / 113966, Japanese Patent Application Publication No. 2013-254183, and Japanese Patent Application Publication No. 2012-189802.

[0129] Silicon compounds can be cited as representative examples of materials for forming low-refractive-index layers. Examples of silicon compounds include: silica compounds; hydrolyzable silanes, their partially hydrolyzed derivatives and dehydration condensates; silicon compounds containing silanol groups; and activated silica obtained by contacting silicates with acids or ion-exchange resins. Other examples of materials for forming low-refractive-index layers include: organic polymers; polymerizable monomers (e.g., (meth)acrylic acid monomers and styrene monomers); and curable resins (e.g., (meth)acrylic acid resins, fluorinated resins, and urethane resins). These materials can be used alone or in combination of two or more.

[0130] In one embodiment, the low-refractive-index layer may contain spaces such as cavities and gaps within it. In this case, the porosity of the low-refractive-index layer is preferably 20% to 60% by volume, more preferably 25% to 55% by volume, even more preferably 30% to 50% by volume, and particularly preferably 35% to 45% by volume. With such a porosity, the refractive index of the low-refractive-index layer can be made to reach an appropriate range, and strength can be ensured. Here, the porosity is a value calculated from the refractive index measured using an ellipsometer, according to the Lorentz-Lorenz formula.

[0131] The size of the holes that can be included in the low-refractive-index layer can be adjusted to a desired size according to the purpose and application. The size of the holes that can be included in the low-refractive-index layer is, for example, 2 nm or more, preferably 5 nm or more, more preferably 10 nm or more, and even more preferably 20 nm or more. On the other hand, the size of the holes that can be included in the low-refractive-index layer is, for example, 500 nm or less, preferably 200 nm or less, and more preferably 100 nm or less. It should be noted that the size of the hole refers to the diameter of the major axis and the diameter of the minor axis of the hole.

[0132] The size of the pores can be quantified using the BET test method. In one embodiment, 0.1 g of the sample (e.g., the fabricated low-refractive-index layer) is introduced into the capillary of a surface area measuring device (e.g., the “ASAP2020” manufactured by McMurray Technology), and then subjected to reduced pressure drying at room temperature for 24 hours to degas the gas contained in the sample. The pore distribution is then determined by plotting adsorption isotherms by adsorbing nitrogen onto the sample. The size of the pores can then be evaluated.

[0133] As an example of a low-refractive-index layer having internal space, a layer may include, for instance, a porous layer and / or an air layer composed of porous bodies in at least a portion thereof. That is, a low-refractive-index layer having internal space includes at least one of the aforementioned porous layer and the aforementioned air layer.

[0134] The low-refractive-index layer typically comprises aerogels and / or particles (e.g., hollow microparticles and / or porous particles). The low-refractive-index layer is preferably a nanoporous layer (specifically, more than 90% of the pores have a diameter of 1 × 10⁻⁶). -1 nm~1×10 3 Porous layers in the nm range).

[0135] As the aforementioned particles, any suitable particles can be used. The particles are typically composed of silica-based compounds. Examples of particle shapes include spherical, plate-like, needle-like, rope-like, and grape-like structures. Examples of rope-like particles include: multiple particles having spherical, plate-like, or needle-like shapes linked together to form a beaded structure; short fibrous particles (e.g., the short fibrous particles described in Japanese Patent Application Publication No. 2001-188104); and combinations thereof. Rope-like particles can be linear or branched. Examples of grape-like particles include: multiple spherical, plate-like, and needle-like particles aggregated to form grape-like clusters. The shape of the particles can be confirmed by observation, for example, using a transmission electron microscope.

[0136] As an example of a low-refractive-index layer, a structure can be described as being composed of one or more constituent units forming a fine porous structure, and these constituent units being bonded to each other (e.g., chemically bonded via catalysis). Examples of shapes for the constituent units include particle-like, fibrous, rod-like, and plate-like forms. The constituent units may have only one shape or may combine two or more shapes.

[0137] As a specific example of a low-refractive-index layer, a porous layer composed of a porous body formed by chemically bonding together microporous particles (hereinafter referred to as microporous particles) can be cited. Such a porous layer can be obtained, for example, by chemically bonding together the microporous particles. The shape of the microporous particles is not particularly limited; for example, they can be spherical or other shapes. Furthermore, the microporous particles can be, for example, sol-gel bead-like particles, nanoparticles (e.g., hollow nano-silica / nano-hollow sphere particles), nanofibers, etc. Microporous particles typically include inorganic materials. Specific examples of inorganic materials include: silicon (Si), magnesium (Mg), aluminum (Al), titanium (Ti), zinc (Zn), and zirconium (Zr). They can be used alone or in combination of two or more. In one embodiment, the aforementioned microporous particles are, for example, microporous particles of a silicon compound, and the aforementioned porous body is, for example, an organosilicon porous body. The microporous particles of the silicon compound, for example, comprise pulverized gel-like silica compounds.

[0138] Another example of a low-refractive-index layer is a layer comprising fibrous materials such as nanofibers, where the entanglement of these fibrous materials creates a spatial structure. Yet another example of a low-refractive-index layer is a layer formed using hollow nanoparticles, nanoclay, or hollow nanospheres and magnesium fluoride. A low-refractive-index layer can be composed of a single constituent material or multiple constituent materials. A low-refractive-index layer can be constructed in a single form as described above, or in multiple forms as described above.

[0139] The aforementioned porous layer can be, for example, a continuous bubble structure. A bubble structure refers to a three-dimensional interconnection of pore structures within a porous body (e.g., an organosilicon porous body), which can also be described as a spatially continuous state of pore structures. By giving the porous layer a bubble structure, the porosity can be increased. While it is difficult to form a bubble structure using individual bubble particles with pore structures, such as hollow particles (e.g., hollow silica), it is easier to form a bubble structure by using, for example, silica sol particles (a pulverized gel-like silicon compound forming a sol), as these particles can have a three-dimensional dendritic structure. Therefore, in a coating film (a coating film containing pulverized gel-like silicon compounds), these dendritic particles settle and accumulate, making it easy to form a bubble structure. The porous layer preferably has a monolithic structure with a bubble structure comprising multiple fine pores. A monolithic structure, for example, refers to a hierarchical structure comprising structures containing nanoscale microcavities and bubble structures formed by the aggregation of nanoscale microcavities. Based on the monolithic structure, for example, it is possible to impart membrane strength by utilizing fine cavities while simultaneously imparting high porosity by utilizing coarse interconnected bubble structures, thereby achieving both membrane strength and high porosity.

[0140] For example, the aforementioned monolithic structure can be formed by controlling the pore distribution of the generated void structure in the gel (gel-like silicon compound) before it is pulverized into silica sol particles. Alternatively, for example, a monolithic structure can be formed by controlling the particle size distribution of the pulverized silica sol particles to a given size during the pulverization of the gel-like silicon compound. It should be noted that the particle size distribution can be measured, for example, using particle size distribution evaluation devices such as dynamic light scattering and laser diffraction, and electron microscopes such as scanning electron microscopy (SEM) and transmission electron microscopy (TEM).

[0141] As described above, the porous layer may contain pulverized particles of a gel-like compound, such as a gel-like silicon compound, which are chemically bonded together. There are no particular limitations on the chemical bonding; examples include cross-linking bonds, covalent bonds, and hydrogen bonds. The volume average particle size of the pulverized particles in the porous layer is, for example, 0.10 μm or more, preferably 0.20 μm or more, and more preferably 0.40 μm or more. On the other hand, the volume average particle size of the pulverized particles in the porous layer is, for example, 2.00 μm or less, preferably 1.50 μm or less, and more preferably 1.00 μm or less. It should be noted that the volume average particle size is an indicator of the deviation in particle size of the pulverized particles and can be determined by particle size distribution measurement.

[0142] The low-refractive-index layer may contain silicon atoms. For example, it is preferable that the silicon atoms contained in the low-refractive-index layer form siloxane bonds. The proportion of unbonded silicon atoms (specifically, residual silanols) in all the silicon atoms contained in the low-refractive-index layer is, for example, less than 50%, preferably less than 30%, and more preferably less than 15%.

[0143] In one embodiment, the material for forming the low refractive index layer can be a coating liquid obtained by dispersing the aforementioned material in a dispersion medium. The dispersion medium can adjust the viscosity, etc., of the coating liquid to a suitable range. As a result, the coatability when forming the low refractive index layer can be improved. The dispersion medium can be a solvent, or it can be a mixed solvent composed of multiple solvents.

[0144] Examples of dispersion media include: alcohols such as ethanol, isopropanol, butanol, tert-butanol, isobutanol, and 2-methoxyethanol (methyl cellosolve); esters such as ethyl acetate and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; ketones such as acetone, methyl ethyl ketone, and methyl isobutyl ketone; and aromatic hydrocarbons such as toluene. These dispersion media can be used alone or in combination. Among these dispersion media, alcohols are more preferred, and isobutanol is even more preferred.

[0145] The mass ratio of the dispersion medium to the total mass of the low-refractive-index layer forming material is, for example, 5% by mass or more, preferably 30% by mass or more, more preferably 40% by mass or more, and for example, 100% by mass or less, preferably 95% by mass or less, more preferably 60% by mass or less. If the content ratio of the dispersion medium is within the above range, the viscosity of the low-refractive-index layer forming material can be stably adjusted to a range suitable for spray-based coating.

[0146] In one embodiment, the aforementioned coating film (a sol coating film containing pulverized gel-like silicon compounds) can be formed using a coating liquid containing microporous particles. By heating (including drying) the coating liquid, the microporous particles can be chemically bonded together. The coating liquid containing microporous particles is, for example, a suspension. A catalyst (crosslinking reaction promoter) that promotes crosslinking bonding between the microporous particles (e.g., the dehydration condensation reaction of residual silanol groups that may be contained in the microporous particles) and / or a substance that generates a catalyst (crosslinking reaction promoter) (catalyst generator) can be added to the coating liquid. Examples of catalysts include, for example, photoactive catalysts and thermally active catalysts. Examples of substances that generate catalysts (catalyst generators) include, for example, photocatalyst generators and thermal catalyst generators. Examples of photocatalyst generators include, for example, photoalkali-generating agents (catalysts that generate alkaline catalysts by light irradiation) and photoacid-generating agents (substances that generate acidic catalysts by light irradiation). For example, the microporous particles are pulverized gel-like compounds (preferably gel-like silicon compounds), and the low-refractive-index layer can have a porous structure composed of a porous body (preferably an organosilicon porous body) containing pulverized gel-like compounds. Such microporous particles can have the three-dimensional structure of the gel-like compound before pulverization dispersed within a three-dimensional basic structure. By using such microporous particles, a structure based on a three-dimensional basic structure can be formed. Specifically, a new structure different from the three-dimensional structure of the gel-like compound can be formed. Thus, the final low-refractive-index layer (porous structure) can, for example, have a low refractive index similar to that of an air layer. Furthermore, by chemically bonding the microporous particles together, the aforementioned three-dimensional basic structure can be immobilized, ensuring sufficient strength in the final low-refractive-index layer (porous structure). Detailed information regarding the specific composition and formation method of the low-refractive-index layer (porous structure) is described, for example, in International Publication No. 2019 / 151073. The description in that publication is incorporated herein by reference.

[0147] The coating thickness of the above-mentioned coating liquid can be set according to the desired thickness of the low refractive index layer. The heating temperature of the coating film (coating liquid) is, for example, 20°C or higher, preferably 50°C or higher. On the other hand, the heating temperature of the coating film (coating liquid) is, for example, 200°C or lower, preferably 150°C or lower. The heating time of the coating film (coating liquid) is, for example, 10 seconds or higher. On the other hand, the heating time of the coating film (coating liquid) is, for example, 24 hours or lower, preferably 1 hour or lower, more preferably 30 minutes or lower, and even more preferably 10 minutes or lower.

[0148] A coating film with a porous structure is formed on a substrate, serving as a precursor to a porous layer (void layer). The following explanation addresses the case where the particles are pulverized gel-like compounds. However, the same method can be used to form a coating film with particles other than pulverized gel-like compounds. The reason why a suitable void structure can be formed in the case of pulverized gel-like compounds can be inferred, for example, as follows. However, this inference does not limit the method of forming the low-refractive-index layer.

[0149] The aforementioned particles (porous particles) are formed by pulverizing a gel-like silicon compound. Therefore, the three-dimensional structure of the gel-like silicon compound before pulverization becomes a dispersed state of a three-dimensional basic structure. For example, the pulverized gel-like silicon compound is sprayed onto a substrate, thereby forming a precursor of a porous structure based on a three-dimensional basic structure. In other words, according to the above method, a new porous structure (three-dimensional basic structure) different from the three-dimensional structure of the gel-like silicon compound, formed by spraying pulverized material, can be formed. Therefore, the resulting low-refractive-index layer can achieve, for example, a low refractive index that functions to the same extent as an air layer.

[0150] In one embodiment, the formation of the low-refractive-index layer may further include a step of heating and drying the coating on the substrate. The heating temperature is, for example, 60°C or higher, preferably 70°C or higher, more preferably 80°C or higher, and for example, 200°C or lower, preferably 120°C or lower, more preferably 100°C or lower. The heating time is not particularly limited as long as it is sufficient to dry the coating sufficiently. In one embodiment, a cross-linking reaction occurs between the multiple particles contained in the coating during this step. Therefore, a three-dimensional basic structure can be immobilized. Thus, the final low-refractive-index layer, despite having a porous structure, maintains sufficient strength and flexibility.

[0151] C-4. Resin layer

[0152] The resin layer may be common to the resin layer in the laminated film described above. Therefore, regarding the resin layer, the description of the resin layer in section B-3 of the laminated film described above can be referenced.

[0153] In the example diagram (e.g.) Figure 4AIn the optical component 200, the resin portion 21 constituting the resin layer 20 is separately disposed on the surface of the low refractive index layer 60 (towards the adhesive layer 10). The resin portion 21 is not a portion of the low refractive index layer 60. By separately disposing the resin portion, the low refractive index layer can have a pattern shape that is opposite to the pattern shape formed by the resin portion.

[0154] In an optical component 201 according to one embodiment of the present invention, the resin portion 21 permeates into the voids of the low refractive index layer 60. Specifically, the resin portion 21 may, for example, permeate into the voids of the low refractive index layer 60. In the optical component according to the embodiment of the present invention, the resin portion may be formed in the thickness direction of the low refractive index layer. The resin portion 21 may be formed on the surface of the low refractive index layer 60 (see reference). Figure 4A Alternatively, it can be formed along the thickness direction of the low-refractive-index layer 60 to the middle of the thickness direction (not shown), or it can be formed along the entire thickness direction of the low-refractive-index layer 60 (see reference). Figure 4B It forms on the surface.

[0155] The resin portion can be a dried, semi-cured, or cured product of the resin composition. More preferably, the resin portion is a cured product of the resin composition.

[0156] C-5. Adhesive layer

[0157] The adhesive layer may be common to the adhesive layer in the laminated film described above. Therefore, regarding the adhesive layer, the description of the adhesive layer in item B-1 of the laminated film described above can be referenced.

[0158] In the optical components of embodiments of the present invention, as described above, the adhesive layer is disposed, for example, on a low-refractive-index layer. One embodiment of the optical component 200 involves peeling off the release liner 30 from the laminated film 100 (see reference). Figure 3 ) and the adhesive layer 10 in the laminated film 100 is bonded to the low refractive index layer 60 to form (refer to Figure 4A ).

[0159] Furthermore, when using the optical component of the embodiments of the present invention in devices such as image display devices and lighting devices, for example, the substrate in the optical component is peeled off from the adhesive layer and the adhesive layer is attached to a light guide layer or other light guide component.

[0160] C-6. Other components

[0161] The optical components of embodiments of the present invention may have configurations other than those described above. For example, one embodiment of the optical component 200 (201) has a release liner 40 on the side of the adhesive layer 10 opposite to the side of the low refractive index layer 60 (see reference). Figure 4A and Figure 4BThe release liner 40 is the same as the second release liner described in item B-4 of the above-described laminated film. Therefore, regarding the release liner, the description of the release liner described in items B-2 and B-4 of the above-described laminated film can be referenced. In the optical component of the embodiments of the present invention, the release liner can be used to protect the adhesive layer until the optical component is supplied for use.

[0162] In the optical component of the embodiments of the present invention, when used in devices such as image display devices and illumination devices, the release liner of the optical component is peeled off and the adhesive layer is attached to the light guide layer or other light guide components. However, it should be noted that in the optical component of the embodiments of the present invention, the release liner is not a necessary component.

[0163] C-7. Manufacturing methods for optical components

[0164] The optical component according to embodiments of the present invention can be manufactured by the following method: for example, after peeling the release liner from the above-described laminated film, an adhesive layer is disposed on the low-refractive-index layer of the laminate comprising a substrate and a low-refractive-index layer, the resin portion is dried as needed, the resin portion is impregnated into the low-refractive-index layer, and / or the resin portion is cured. Hereinafter, a method for manufacturing the optical component according to embodiments of the present invention will be specifically described. As described above, the optical component according to embodiments of the present invention can employ the laminated film of the above-described embodiments, and therefore can include all or part of the method for manufacturing the laminated film of the above-described embodiments. Therefore, in the method for manufacturing the optical component according to embodiments of the present invention, the descriptions common to the method for manufacturing the laminated film described above are referenced from the descriptions in paragraphs B-5 above, and are appropriately omitted.

[0165] For example, firstly, the laminated film, which has been wound and stored in a roll, is unwound. The unwound size can be any appropriate size depending on the application. This prepares a strip of laminated film. It should be noted that the unwound rolled laminated film and / or the unwound strip of laminated film can also be cut to the desired size to produce a single-sheet laminated film.

[0166] Next, the release liner is peeled off from the released laminate. This exposes the adhesive layer and resin layer (resin portion) of the laminate. This laminate, that is, the laminate containing the support member, adhesive layer, and resin layer, is also referred to as the second laminate.

[0167] Next, for example, Figure 5As shown, the adhesive layer 10 and resin layer 20 (resin portion 21) of the second laminate 120 are overlapped and bonded to the low-refractive-index layer 60 of the laminate 130 (hereinafter also referred to as the third laminate), which includes a substrate 50 and a low-refractive-index layer 60. That is, the adhesive layer 10 and resin layer 20 (resin portion 21) of the second laminate 120 are disposed on the low-refractive-index layer 60 of the third laminate 130. It should be noted that the low-refractive-index layer 60 of the third laminate 130 may also be disposed on the adhesive layer 10 and resin layer 20 of the second laminate 120.

[0168] A laminate obtained by configuring a third laminate on a second laminate, and / or a laminate by configuring a second laminate on a third laminate, is sometimes referred to as a fourth laminate. An optical component according to one embodiment of the present invention may include a fourth laminate.

[0169] Alternatively, by overlapping and bonding the adhesive layer and resin layer with the low-refractive-index layer, the separately configured resin portion can be transferred to the low-refractive-index layer. However, in the fourth laminate, the resin portion may not be transferred.

[0170] In one embodiment, the resin portion is impregnated into the low-refractive-index layer of the fourth laminate. By impregnating the resin portion into the low-refractive-index layer, the resin portion can be formed along the thickness direction of the low-refractive-index layer. Preferably, the resin portion can also be formed along the entire thickness direction of the low-refractive-index layer (see reference). Figure 4B The impregnation of the resin layer into the low-refractive-index layer can be carried out by any suitable method. For example, impregnation methods include: impregnating the resin layer (resin part) by its own weight at room temperature and pressure; and / or, impregnating the resin layer (resin part) by applying pressure under any suitable conditions; and / or, impregnating the resin layer (resin part) by heating. As long as it does not cause the resin part to cure, the heating conditions when heating is carried out can be any suitable conditions, for example, the heating temperature can be set to about 100°C and the heating time can be set to more than 1 minute and less than 10 minutes.

[0171] In this way, optical components according to embodiments of the present invention can be manufactured.

[0172] In one embodiment, the resin portion in the fourth laminate is dried. Specifically, volatile components that may be contained in the resin portion of the fourth laminate are evaporated under any suitable conditions. The resin portion can be heated while the volatile components are evaporating. When heating is performed, the heating conditions during drying can be adjusted appropriately based on the composition of the resin composition, etc. The heating temperature is, for example, 80°C or higher and 150°C or lower. The heating time is, for example, 1 minute or more and 1 hour or less. Thus, an optical component in which the resin layer contains a dried resin composition can be obtained.

[0173] The drying of the resin portion in the fourth laminate can be performed either before or after impregnation of the low-refractive-index layer. When heating the resin portion before impregnation, it is preferable to perform heating at a temperature below the temperature at which the resin portion cures. The heating conditions can be adjusted appropriately based on the composition of the resin composition, etc. For example, the heating temperature is 80°C or higher and 150°C or lower. The heating time is, for example, 1 minute or more and 1 hour or less. Thus, an optical component in which the resin layer comprises a dried product and / or a semi-cured product of the resin composition can be obtained.

[0174] In one embodiment, the resin portion is cured after impregnating the low-refractive-index layer. Curing of the resin portion can preferably be performed by irradiating the resin layer of the fourth laminate with light. The irradiating light can be any suitable light source, depending on the composition of the resin composition, the type and proportion of the resin material, the type of additives, etc. For example, the light source can be ultraviolet light. The irradiation conditions can also be any suitable conditions. Thus, an optical component in which the resin layer contains a cured resin composition can be obtained.

[0175] In one embodiment, the curing of the resin portion can also combine light-curing and heat-curing. Light-curing (photocuring) can be the same as described above. In heat-curing (heat curing), the heating conditions can be set to any suitable heating temperature and / or heating time. The heating temperature is, for example, 60°C or higher and 150°C or lower. The heating time is, for example, 1 minute or higher and 60 minutes or lower. Furthermore, when the resin layer is heated, the resin portion (essentially a resin composition) impregnated into the low-refractive-index layer can undergo cross-linking within the low-refractive-index layer. Thus, the separately configured resin portion can be transferred to the low-refractive-index layer.

[0176] In this way, an optical component according to one embodiment of the present invention can be manufactured.

[0177] The manufacturing method of the optical component according to the embodiments of the present invention is not limited to the method described above, and may include any appropriate steps within the limits that do not impair the effect of the present invention.

[0178] The elongated optical components that can be obtained by the above manufacturing method can be cut into any appropriate size to make a single-piece optical component of appropriate size.

[0179] Example

[0180] The present invention will now be described in detail with reference to the embodiments, but the present invention is not limited to these embodiments.

[0181] (1) Ink height and ink diameter before pressurization

[0182] The shape of the coating (resin layer) in the pre-pressurized laminated film test piece (hereinafter referred to as the pre-pressurization test piece) was observed using a laser microscope (Keyence VK-X1000). The ink height and ink diameter were calculated from the images obtained through observation.

[0183] (2) The height, diameter and shape change rate of the ink after pressure application

[0184] A 90 μm thick test piece was cut from the unpressurized test piece. Two PET films (38 μm thick, 10 μm thick adhesive layer) were then bonded to both sides of the unpressurized test piece along its thickness. The test piece was then clamped and pressurized at 25°C and 0.40 MPa for 13 hours. This yielded a test piece of the laminated film after pressurization (hereinafter referred to as the pressurized test piece). The shape of the coating (resin layer) in the pressurized test piece was observed using a laser microscope (Keyence VK-X1000). The images obtained through observation were processed to calculate the ink height and ink diameter.

[0185] The value obtained by dividing the ink diameter of the test piece after pressure application by the ink diameter of the test piece before pressure application is used as the "ink shape change rate".

[0186] (3) Pressure resistance

[0187] Based on the above-mentioned ink shape change rate and the results of the ink image after pressure, the pressure resistance of the laminated films of the Examples and Comparative Examples was evaluated based on the following criteria.

[0188] A (Good): The ink shape change rate is less than 2.0 times, and no ink bulging is observed in the image.

[0189] B (Moderate): The ink shape change rate is more than 2.0 times but less than 3.0 times, and no ink bulging is observed in the image.

[0190] C (Defective): Ink shape change rate exceeds 3.0 times, and ink bulging and / or expansion are observed in the image.

[0191] [Manufacturing Example 1] Preparation of adhesive and fabrication of adhesive layer

[0192] The adhesive layer was made in the order of (i) to (iii) below.

[0193] (i) Preparation of (meth)acrylic acid polymer (A) solution

[0194] A monomer mixture containing 79.5 parts butyl acrylate, 15 parts N-acryloylmorpholine, 5 parts acrylic acid, and 0.5 parts 4-hydroxybutyl acrylate was added to a four-necked flask equipped with a stirrer, thermometer, nitrogen inlet tube, and condenser. Next, 0.1 parts of polymerization initiator (2,2'-azobisisobutyronitrile) and 70 parts of ethyl acetate were added relative to 100 parts of the monomer mixture, and the flask was purged with nitrogen while stirring. The liquid temperature in the flask was then heated to approximately 55°C, and the polymerization reaction was carried out for 2 hours while maintaining this temperature. This yielded a solution of a (meth)acrylic acid polymer (A) with a weight-average molecular weight (Mw) of 3,000,000 and a polydispersity index (Mw / Mn) of 2.5.

[0195] (ii) Preparation of (meth)acrylic adhesive compositions

[0196] A solution of an acrylic adhesive composition (adhesive 1) was prepared by mixing 100 parts of the solid component of the solution of the (meth)acrylic polymer (A) described above with 0.2 parts of an isocyanate crosslinking agent (trade name "Coronate L" manufactured by Nippon Polyurethane Industries, Ltd.: an adduct of trimethylolpropane toluene diisocyanate) and 0.2 parts of an epoxy crosslinking agent (trade name "Tetrad C" manufactured by Mitsubishi Gas Chemical Co., Ltd.: 1,3-tris(N,N-diglycidylaminomethyl)cyclohexane).

[0197] (iii) Preparation of adhesive layer

[0198] On one side of a polyethylene terephthalate (PET) film (manufactured by Mitsubishi Chemical Polyester Film Co., Ltd., trade name "MRF38") that has been surface-treated with a silicone-based release agent, a solution of the acrylic adhesive composition described in (ii) above was applied to achieve a dry adhesive layer thickness of 10 μm, and then dried at 155°C for 1 minute. This produced a laminate (PET film / adhesive layer) having an adhesive layer on the PET film.

[0199] The energy storage modulus of the adhesive layer is 1.1 × 10⁻⁶. 5 Pa. The storage modulus was determined according to JIS K7244-1, by reading the value at 23°C when measured at a frequency of 1Hz in the range of -50°C to 150°C with a heating rate of 5°C / min.

[0200] The nanoindentation hardness of the adhesive layer is 1.08 MPa. The nanoindentation hardness was determined according to ISO 14577 by using a nanoindenter (Oxford Instruments model "MFP-3D-SA") to indent 2000 nm relative to the above-mentioned laminate (dimensions: width 10 mm, length 10 mm, thickness 48 mm) and the AFM force curve method.

[0201] [Example 1]

[0202] As a support member and adhesive layer, the laminate (first laminate) of the above-described manufacturing example 1 is prepared, as a release liner, the release liner 1 described below is prepared, and as a resin layer, the resin composition (ink) is prepared, the ink containing the resin material 1 described below is prepared.

[0203] Ink was applied to the adhesive layer of the first laminate. The application was performed by inkjet printing, as described below. Specifically, ink was first injected into the injection port of the inkjet apparatus. Furthermore, the first laminate was positioned below the nozzle of the inkjet apparatus, with the adhesive layer facing the nozzle side.

[0204] Next, ink is ejected from the nozzle of the inkjet device in such a manner that the ink droplets reach the "ink height" and "ink diameter" before pressurization as described in Table 1. As a result, a resin layer, i.e., a pattern formed by the resin portion (ink), is formed on the adhesive layer.

[0205] Next, the first laminate was heated. Heating dried the resin portion. Then, a release liner was placed on the adhesive layer containing the resin layer, temporarily adhering the release liner. This produced the laminated film (laminated film before pressure).

[0206] The resulting laminated membrane was used for the determination and evaluation described in (1) above.

[0207] In addition, the obtained laminated film was pressurized under the conditions described in (2) above, thereby producing pressurized test pieces, which were used for the evaluation in (2) and (3) above.

[0208] [Examples 2-7 and Comparative Examples 1-3]

[0209] The method for making the ink height and ink diameter of the ink containing resin material 1 before pressurization reach the values ​​recorded in Table 1 was changed. Otherwise, a laminated film (laminated film before pressurization and laminated film after pressurization) was made in the same manner as in Example 1.

[0210] The resulting laminated film was subjected to the same evaluation as in Example 1.

[0211] The materials shown in Table 1 are as follows.

[0212] (Resin material)

[0213] • Resin Material 1: A resin material prepared by dissolving a urethane photocurable resin (manufactured by Daicel Allenx Co., Ltd.: trade name KRM8904. Composition resin: urethane acrylate. Thickness: 1~4μm.) at a solid content concentration of 12~35% by weight, together with the initiator 1-hydroxycyclohexylphenyl ketone, in the solvent diethylene glycol ethyl methyl ether (EDM).

[0214] (Peel-off liner)

[0215] • Release liner 1: Manufactured by Mitsubishi Chemical Polyester Film Co., Ltd.: Trade name "MHE38". Thickness: 38μm.

[0216]

[0217] As can be clearly seen from Table 1, according to the embodiments of the present invention, the shape change rate of the ink diameter (ink shape change rate) reaches less than 3.0 times, and the pressure resistance is excellent. That is, according to the embodiments of the present invention, the deformation of the resin portion is suppressed, and as a result, a laminated film capable of suppressing the shape change of the ink pattern in the resin layer is obtained.

[0218] Industrial applicability

[0219] The laminated films of the embodiments of the present invention can be suitably used to fabricate optical components. In particular, the laminated films of the embodiments of the present invention can be suitably used to fabricate optical components with light distribution functions.

Claims

1. A laminated film comprising, sequentially, an adhesive layer, a resin layer, and a release liner, The resin layer comprises resin portions disposed separately from each other on the adhesive layer. The equivalent diameter of the resin portion is less than 150 μm.

2. The laminated film according to claim 1, wherein, The resin portion comprises at least one selected from the dried product, semi-cured product, and cured product of the resin composition.

3. The laminated film according to claim 2, wherein, The resin composition contains a photocurable resin.

4. The laminated film according to claim 3, wherein, The photocurable resin contains at least one resin selected from urethane (meth)acrylate, epoxy (meth)acrylate and polyester (meth)acrylate.

5. The laminated film according to claim 1, wherein, When measured according to ISO 14577 using a nanoindenter with the indenter pressed into the nanoindenter at 2000 nm, the nanoindentation hardness of the adhesive layer is 0.5 MPa or higher.

6. The laminated film according to claim 1, wherein, The area of ​​the resin portion is less than 60% of the total area of ​​the adhesive layer.

7. A method for manufacturing a laminated film, the method comprising: The resin portions constituting the resin layers are disposed separately on the adhesive layer of the laminate having support members and adhesive layers; as well as A release liner is configured to cover the laminate and the resin portion.

8. The method for manufacturing a laminated film according to claim 7, the method comprising: The resin section is heated after it has been prepared.

9. The method for manufacturing a laminated film according to claim 7, the method comprising: After the release liner is configured, it is wound into a roll.

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