Film mirror laminate and mirror member

Abstract

To provide a mirror member which can be easily applicable in a complex curved surface shape or the like with good productivity and is excellent in a mirror surface property.SOLUTION: There is provided a film mirror laminate comprising: an adhesive layer; a substrate film; a metal reflective layer; and an optical adjustment layer in this order, wherein, when light is incident from the optical adjustment layer side at an incident angle of 60° on a sample in which a surface of an adhesive layer-side of the film mirror laminate is attached to a glass plate, a reflection image clarity at an optical comb width of 0.125 mm is 60% or more.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a film mirror laminate and a mirror member. [Background technology]

[0002] A driver of a vehicle drives while gazing ahead through the windshield and visually checking the instruments on the instrument panel. In other words, the driver's line of sight moves from the front to the instruments below. If the driver could see the instruments while keeping his or her eyes on the front, there would be no need to move his or her line of sight, and this would be expected to improve drivability (and ultimately safety). Based on this knowledge, head-up display devices have been developed and are now being put to practical use.

[0003] In a head-up display device, an image from a light source is projected as a virtual image on the windshield inside the dashboard device, and is visually recognized by the driver. In order to project image information from the light source without distortion, a mirror body with high specularity is required. Also, in order to project image information from the light source without reducing its brightness, a mirror body with high visible light reflectance is required. From the viewpoint of improving driving safety, head-up displays that require less eye movement are attracting more and more attention, and the demand for mirror bodies used as reflectors is also increasing. In addition, for reasons such as low risk of damage in accidents such as vehicle collisions and light weight, plastic substrates, particularly polycarbonate substrates due to their high heat resistance, are used as the support substrate constituting the mirror body.

[0004] In the conventional manufacturing method of mirror-surface bodies, a batch-type deposition / sputtering device is generally used to form a metal thin film on a support substrate such as a polycarbonate substrate (for example, Patent Document 1). However, the batch-type manufacturing method has low production efficiency, and there is a problem of supply shortage while the demand for mirror-surface bodies is increasing day by day, so there is a demand for mirror-surface bodies that can be manufactured with high productivity. In addition, mirror-surface bodies are required to have high reflectance and suppress distortion of reflected light.

[0005] Therefore, a method for manufacturing a reflective mirror using a reflective film that can be attached to a support has been studied. For example, Patent Document 2 discloses that a reflective mirror including a substrate and a reflective sheet on which a reflective film is formed is manufactured by insert molding. Insert molding has high productivity because the reflective sheet can be molded integrally with the substrate. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2009-265287 A [Patent Document 2] JP 2019-28422 A Summary of the Invention [Problem to be solved by the invention]

[0007] As described above, in order to project image information from a light source without distortion, the mirror needs to have high specularity. However, with conventional techniques, it has been difficult to obtain sufficient specularity.

[0008] The present invention was completed in consideration of the above, and its object is to provide a mirror member with excellent specularity, and a film mirror laminate that is highly productive, can be easily adapted to complex curved surface shapes, and can provide a mirror member with excellent specularity. [Means for solving the problem]

[0009] As a result of extensive research, the inventors have discovered that by setting the reflection image clarity of a mirror member in which the adhesive layer side of a film mirror laminate is attached to a supporting substrate within a specific range, it is possible to produce a mirror member with excellent mirror surface with good productivity by laminating the film mirror laminate to supporting substrates of complex shapes that were difficult to produce using conventional batch processing, thereby solving the above-mentioned problem.

[0010] That is, the present invention is as follows. [1] A film mirror laminate having a pressure-sensitive adhesive layer, a substrate film, a metal reflective layer, and an optical adjustment layer in this order, A film mirror laminate, in which a reflection image clarity at an optical comb width of 0.125 mm is 60% or more when light is incident on a sample in which the surface of the adhesive layer side of the film mirror laminate is attached to a glass plate from the optical adjustment layer side at an incident angle of 60°. [2] The film mirror laminate according to [1], wherein the optical adjustment layer comprises a low refractive index layer and a high refractive index layer. [3] The film mirror laminate according to [2], wherein the low refractive index layer contains silicon oxide. [4] The film mirror laminate according to [2], wherein the high refractive index layer contains niobium oxide. [5] The film mirror laminate according to [1], wherein the metal reflective layer contains at least one metal selected from aluminum (Al), zinc (Zn), lead (Pb), copper (Cu), and silver (Ag), and an alloy mainly composed of the metal. [6] A mirror member comprising the film mirror laminate according to any one of [1] to [5] and a supporting substrate, the surface of the film mirror laminate on the side of the pressure-sensitive adhesive layer being attached to the supporting substrate. Effect of the Invention

[0011] The film mirror laminate of the present invention can be easily applied to complex curved surface shapes and the like with good productivity, and can provide a mirror member with excellent mirror surface properties. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic cross-sectional view of a film mirror laminate according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic cross-sectional view of a film mirror laminate according to one embodiment of the present invention. [Diagram 3] FIG. 3 is a schematic cross-sectional view of a mirror member according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the preferred embodiments. However, the present invention is not limited to the preferred embodiments described below.

[0014] [Film mirror laminate] A schematic cross-sectional view of a film mirror laminate 1 according to one embodiment of the present invention is shown in Fig. 1. The film mirror laminate 1 has an adhesive layer 10, a base film 11, a metal reflective layer 12, and an optical adjustment layer 13 in this order, and when light is incident on a sample of the film mirror laminate 1 with the adhesive layer 10 side attached to a glass plate at an incident angle of 60° from the optical adjustment layer 13 side, the reflection image clarity at an optical comb width of 0.125 mm is 60% or more.

[0015] The film mirror laminate 1 according to the embodiment of the present invention can be used by attaching the surface of the pressure-sensitive adhesive layer 10 opposite to the substrate film 11 to a supporting substrate. In the film mirror laminate 1 according to the embodiment of the present invention, a measurement value of reflection image clarity of 60% or more at an optical comb width of 0.125 mm when light is incident from the optical adjustment layer side at an incident angle of 60° on a sample in which the adhesive layer side of the film mirror laminate is attached to a glass plate represents the mirror performance of reflection. Therefore, by making the reflection image clarity of 60% or more at an optical comb width of 0.125 mm when light is incident from the optical adjustment layer side at an incident angle of 60°, a film mirror laminate can be obtained that can form a mirror member with excellent specular properties.

[0016] The film mirror laminate 1 according to the embodiment of the present invention preferably has a reflection image clarity of 65% or more at an optical comb width of 0.125 mm, more preferably 70% or more, and even more preferably 80% or more.

[0017] Furthermore, when light is incident on the above sample from the optical adjustment layer side at an incident angle of 60°, the reflection image clarity at an optical comb width of 0.25 mm is preferably 85% or more, more preferably 90% or more, and even more preferably 95% or more. When light is incident on the above sample from the optical adjustment layer side at an incidence angle of 60°, the reflection image clarity at an optical comb width of 0.5 mm is preferably 90% or more, more preferably 95% or more, and even more preferably 99% or more. When light is incident on the above sample from the optical adjustment layer side at an incidence angle of 60°, the reflection image clarity at an optical comb width of 1.0 mm is preferably 90% or more, more preferably 95% or more, and even more preferably 99% or more. When light is incident on the above sample from the optical adjustment layer side at an incidence angle of 60°, the reflection image clarity at an optical comb width of 2.0 mm is preferably 90% or more, more preferably 95% or more, and even more preferably 99% or more.

[0018] The above-mentioned reflected image clarity is measured in accordance with JIS K7374 (Plastics - Determination of image clarity) using a sample in which the surface of the pressure-sensitive adhesive layer side of the film mirror laminate 1 is attached to a glass plate. The specific measurement procedure and conditions for the reflection image clarity can be set according to the measurement conditions described in the Examples below, or so as to obtain results equivalent to or corresponding to those obtained according to the measurement conditions. In the embodiment of the present invention, the higher the reflection image clarity, the less distortion and the higher the resolution of the image, and the more likely it is that the specularity will improve when the film mirror laminate is applied to a mirror member. If the reflection image clarity at an optical comb width of 0.125 mm is less than 60%, the specularity will decrease when the film mirror laminate is applied to a mirror member.

[0019] <Base film> The base film 11 is not particularly limited, and may be a film made of a homopolymer or copolymer such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polybutylene terephthalate, polyamide, polyvinyl chloride, polycarbonate (PC), cycloolefin polymer (COP), polystyrene, polypropylene (PP), polyethylene, polycycloolefin, polyurethane, acrylic (PMMA), or ABS. These materials are transparent and have little optical absorption, and do not affect the visual effect. However, since various layers are formed on the base film 11 later, it is preferable that the material can withstand high temperatures such as deposition and sputtering, and therefore, among the above materials, for example, polyethylene terephthalate, polyethylene naphthalate, acrylic, polycarbonate, cycloolefin polymer, ABS, polypropylene, and polyurethane are preferable. Among them, polyethylene terephthalate, cycloolefin polymer, polycarbonate, and acrylic are preferable because they have a good balance between heat resistance and cost. The base film 11 may be a single-layer film or a laminated film. From the viewpoint of ease of processing, the thickness is preferably, for example, about 6 μm to 250 μm. The lower limit of the thickness is more preferably 15 μm or more. The upper limit of the thickness is more preferably 200 μm or less, and further preferably 150 μm or less. In order to strengthen the adhesive force with the layer formed on the base film, a plasma treatment or an easy-adhesion treatment may be performed.

[0020] If necessary, a hard coat layer such as a smooth or antiglare hard coat layer may be formed on the substrate film 11. By providing the hard coat layer, scratch resistance can be improved. The hard coat layer can be formed from a hard coat composition. More specifically, the hard coat layer can be formed by applying a solution containing a curable resin as a hard coat composition onto the substrate film 11. Examples of the curable resin include thermosetting resin, ultraviolet curing resin, and electron beam curing resin. Examples of the type of curable resin include various resins such as polyester, acrylic, urethane, acryl urethane, amide, silicone, silicate, epoxy, melamine, oxetane, and acryl urethane. One or more of these curable resins can be appropriately selected and used. Among these, acrylic resins, acryl urethane resins, and epoxy resins are preferred because they have high hardness, can be cured with ultraviolet light, and are excellent in productivity.

[0021] The thickness of the hard coat layer is preferably 0.5 μm or more, more preferably 1.0 μm or more, and is preferably 10 μm or less, more preferably 7.0 μm or less, and even more preferably 5.0 μm or less. The thickness of the hard coat layer can be measured, for example, using a film thickness meter (digital dial gauge).

[0022] <Adhesive layer> The film mirror laminate 1 according to the embodiment of the present invention can be used as a mirror member 100 by attaching the surface on the pressure-sensitive adhesive layer 10 side to a supporting substrate 21, for example, as shown in FIG. The adhesive layer 10 can be formed from an adhesive. The adhesive forming the adhesive layer 10 is preferably a transparent adhesive, and for example, any of acrylic adhesives, rubber adhesives, silicone adhesives, polyester adhesives, urethane adhesives, epoxy adhesives, and polyether adhesives can be used alone or in combination of two or more. From the viewpoints of transparency, processability, durability, etc., it is preferable to use an acrylic adhesive.

[0023] The adhesive forming the adhesive layer 10 is preferably formed from an adhesive composition (hereinafter, sometimes simply referred to as "adhesive composition") containing a base polymer. Any known polymer used in adhesives can be used as the base polymer. Here, the base polymer refers to the main component of the polymer contained in the adhesive composition. In this specification, the term "main component" refers to a component contained in an amount of more than 50 mass %, unless otherwise specified.

[0024] (Adhesive composition) The pressure-sensitive adhesive composition preferably contains a (meth)acrylic polymer as a base polymer. Here, (meth)acrylate refers to acrylate and / or methacrylate. A part of the monomers constituting the (meth)acrylic polymer may be contained in the pressure-sensitive adhesive composition as unreacted monomers.

[0025] The (meth)acrylic polymer in the embodiment of the present invention is preferably a hydroxyl group-containing (meth)acrylic polymer containing an alkyl (meth)acrylate and a hydroxyl group-containing monomer as monomer units. The method of introducing the hydroxyl group is not particularly limited, but for example, a method of copolymerizing a hydroxyl group-containing monomer can be easily performed.

[0026] In the embodiment of the present invention, the (meth)acrylic polymer refers to an acrylic polymer and / or a methacrylic polymer, the (meth)acrylate refers to an acrylate and / or a methacrylate, and the alkyl (meth)acrylate refers to an alkyl acrylate and / or an alkyl methacrylate.

[0027] Examples of the alkyl (meth)acrylate include methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, etc. These compounds may be used alone or in combination of two or more.

[0028] Examples of the hydroxyl group-containing monomer include 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 6-hydroxyhexyl (meth)acrylate, 8-hydroxyoctyl (meth)acrylate, 10-hydroxydecyl (meth)acrylate, 12-hydroxylauryl (meth)acrylate, (4-hydroxymethylcyclohexyl)methyl acrylate, N-methylol (meth)acrylamide, N-hydroxy (meth)acrylamide, vinyl alcohol, allyl alcohol, 2-hydroxyethyl vinyl ether, 4-hydroxybutyl vinyl ether, diethylene glycol monovinyl ether, etc. These monomers may be used alone or in combination of two or more.

[0029] The hydroxyl group-containing monomer may be used alone or in combination of two or more kinds, but the total content is preferably 1 to 40 parts by mass, more preferably 2 to 30 parts by mass, relative to 100 parts by mass of the (meth)acrylic polymer. By copolymerizing the hydroxyl group-containing monomer, a hydroxyl group-containing (meth)acrylic polymer having reactive sites due to crosslinking or the like is obtained.

[0030] The (meth)acrylic polymer used in the embodiment of the present invention preferably has a weight-average molecular weight of about 300,000 to 2,500,000. If the weight-average molecular weight is less than 300,000, the adhesive composition tends to have a low cohesive force, resulting in adhesive residue. The weight-average molecular weight is measured by GPC (gel permeation chromatography).

[0031] In order to easily balance the adhesive properties, the (meth)acrylic polymer preferably has a glass transition temperature (Tg) of 0° C. or lower (usually −100° C. or higher), and more preferably −10° C. or lower. If the glass transition temperature is higher than 0° C., the polymer becomes less likely to flow. The glass transition temperature (Tg) of the (meth)acrylic polymer can be adjusted to fall within the above range by appropriately changing the monomer components and composition ratio used.

[0032] In addition to the above-mentioned monomers, other polymerizable monomers such as polymerizable monomers for adjusting the glass transition point or peelability of the (meth)acrylic polymer can be used as long as the effects of the present invention are not impaired.

[0033] Examples of other polymerizable monomers that can be used in the (meth)acrylic polymer include components that improve cohesive strength and heat resistance, such as sulfonic acid group-containing monomers, phosphoric acid group-containing monomers, cyano group-containing monomers, vinyl ester monomers, and aromatic vinyl monomers, and components that improve adhesive strength or have a functional group that acts as a crosslinking base, such as acid anhydride group-containing monomers, amide group-containing monomers, amino group-containing monomers, epoxy group-containing monomers, N-acryloylmorpholine, and vinyl ether monomers. These monomer compounds may be used alone or in combination of two or more.

[0034] Examples of the cyano group-containing monomer include acrylonitrile and methacrylonitrile.

[0035] Examples of the vinyl ester monomer include vinyl acetate, vinyl propionate, and vinyl laurate.

[0036] Examples of the aromatic vinyl monomer include styrene, chlorostyrene, chloromethylstyrene, and α-methylstyrene.

[0037] Examples of the amide group-containing monomer include acrylamide, diethylacrylamide, and N-vinyl-2-pyrrolidone.

[0038] Examples of the amino group-containing monomer include N,N-dimethylaminoethyl (meth)acrylate, N,N-dimethylaminopropyl (meth)acrylate, N-(meth)acryloylmorpholine, and (meth)acrylic acid alkylaminoalkyl esters.

[0039] Examples of the epoxy group-containing monomer include glycidyl (meth)acrylate and allyl glycidyl ether.

[0040] Examples of the vinyl ether monomer include methyl vinyl ether, ethyl vinyl ether, and isobutyl vinyl ether.

[0041] In the embodiment of the present invention, the other polymerizable monomers may be used alone or in combination of two or more kinds. The total content is preferably 0 to 40 parts by mass, and more preferably 0 to 30 parts by mass, relative to 100 parts by mass of the (meth)acrylic polymer.

[0042] The polymerization method for the (meth)acrylic polymer is not particularly limited, and any known polymerization method such as solution polymerization, emulsion polymerization, suspension polymerization, UV polymerization, etc. The copolymer obtained may be any of a random copolymer, a block copolymer, a graft copolymer, etc.

[0043] In an embodiment of the present invention, the pressure-sensitive adhesive composition may contain a polymer component other than the above-mentioned base polymer.

[0044] In an embodiment of the present invention, the pressure-sensitive adhesive composition preferably contains a crosslinking agent, and an isocyanate-based crosslinking agent is preferably used as the crosslinking agent. The isocyanate-based crosslinking agent is used to impart adhesion and cohesion.

[0045] As the isocyanate-based crosslinking agent, a polyfunctional isocyanate compound is used, and includes various compounds having two or more isocyanate groups in the molecule.

[0046] Examples of the isocyanate compound include lower aliphatic polyisocyanates such as butylene diisocyanate and hexamethylene diisocyanate; alicyclic isocyanates such as cyclopentylene diisocyanate, cyclohexylene diisocyanate and isophorone diisocyanate; aromatic isocyanates such as 2,4-tolylene diisocyanate, 4,4'-diphenylmethane diisocyanate and xylylene diisocyanate; and isocyanate adducts such as trimethylolpropane / tolylene diisocyanate trimer adduct (product name: Coronate L, manufactured by Nippon Polyurethane Industry Co., Ltd.), trimethylolpropane / hexamethylene diisocyanate trimer adduct (product name: Coronate HL, manufactured by Nippon Polyurethane Industry Co., Ltd.), and isocyanurate of hexamethylene diisocyanate (product name: Coronate HX, manufactured by Nippon Polyurethane Industry Co., Ltd.). Among these, those having an isocyanurate ring are particularly preferred, and examples thereof include polyisocyanate having a long-chain alkylene diol modified isocyanurate ring (Burnoc DN-995, manufactured by Dainippon Ink and Chemicals, Inc.), isocyanurate of hexamethylene diisocyanate (product name: Coronate HX, manufactured by Nippon Polyurethane Industry Co., Ltd.), etc. These compounds may be used alone or in combination.

[0047] The content of the crosslinking agent used in the embodiment of the present invention may be such that it does not affect the adhesive properties, but it is usually contained in an amount of 0.2 to 10 parts by mass, preferably 0.5 to 8 parts by mass, and more preferably 1 to 6 parts by mass, per 100 parts by mass of the (meth)acrylic polymer.

[0048] In the embodiment of the present invention, the pressure-sensitive adhesive composition preferably contains a polyfunctional (meth)acrylic monomer such as 1,6-hexanediol diacrylate as a crosslinking component. Note that the (meth)acrylic monomer in the embodiment of the present invention refers to an acrylic monomer and / or a methacrylic monomer. The polyfunctional (meth)acrylic monomer is usually contained in an amount of 0.2 to 10 parts by mass, preferably 0.5 to 8 parts by mass, and more preferably 1 to 6 parts by mass, per 100 parts by mass of the (meth)acrylic polymer.

[0049] In addition, the acrylic adhesive may also contain crosslinking agents other than those exemplified above (polyamine compounds, melamine resins, aziridine derivatives, urea resins), polymerization initiators, tackifiers, plasticizers, silane coupling agents, colorants, powders such as pigments, dyes, surfactants, surface lubricants, leveling agents, softeners, antioxidants, antistatic agents, antiaging agents, light stabilizers, ultraviolet absorbers, polymerization inhibitors, inorganic or organic fillers, metal powders, particulate or foil-like materials, etc. These components may be used alone or in combination of two or more.

[0050] (Adhesive strength of adhesive layer) In the film mirror laminate according to the embodiment of the present invention, from the viewpoint of preventing peeling at the interface between the base film and the pressure-sensitive adhesive layer, the adhesive strength of the pressure-sensitive adhesive layer to the base film is preferably 5N / 25mm or more, more preferably 10N / 25mm or more, and even more preferably 15N / 25mm or more. Also, it is preferably 40N / 25mm or less, more preferably 35N / 25mm or less, and even more preferably 30N / 25mm or less. In addition, in the film mirror laminate according to the embodiment of the present invention, from the viewpoint of preventing peeling at the interface between the adhesive layer and the support substrate when the surface of the adhesive layer side of the film mirror laminate is attached to the support substrate, the adhesive strength of the adhesive layer to the support substrate is preferably 5N / 25mm or more, more preferably 10N / 25mm or more, and even more preferably 15N / 25mm or more. In addition, from the viewpoint of reworkability (treatment of peeling and reattaching when there is a problem with the attachment), it is preferably 40N / 25mm or less, more preferably 35N / 25mm or less, and even more preferably 30N / 25mm or less.

[0051] (Method of forming pressure-sensitive adhesive layer) The pressure-sensitive adhesive layer can also be formed, for example, by applying the pressure-sensitive adhesive composition onto a substrate film and then drying to remove the solvent, etc. When applying the pressure-sensitive adhesive composition, one or more solvents may be added as appropriate. The pressure-sensitive adhesive layer can also be formed, for example, by laminating the surface of the pressure-sensitive adhesive layer in a laminate of a pressure-sensitive adhesive layer formed on a release liner using the pressure-sensitive adhesive composition and a release liner to a base film.

[0052] The thickness of the pressure-sensitive adhesive layer is preferably from 10 to 70 μm, more preferably from 15 to 65 μm, even more preferably from 15 to 60 μm, and even more preferably from 20 to 55 μm. The thickness of the pressure-sensitive adhesive layer can be measured with a dial gauge.

[0053] Various methods can be used to apply the pressure-sensitive adhesive composition, specifically, for example, roll coating, kiss roll coating, gravure coating, reverse coating, roll brushing, spray coating, dip roll coating, bar coating, knife coating, air knife coating, curtain coating, lip coating, extrusion coating using a die coater, etc.

[0054] The heating and drying temperature is preferably about 30°C to 200°C, more preferably 40°C to 180°C, and even more preferably 80°C to 160°C. By setting the heating temperature within the above range, it is possible to obtain an adhesive layer having excellent adhesive properties. The drying time can be appropriately selected. The drying time is preferably about 5 seconds to 20 minutes, more preferably 30 seconds to 10 minutes, and even more preferably 1 minute to 8 minutes.

[0055] When the pressure-sensitive adhesive composition is an active energy ray-curable pressure-sensitive adhesive, the pressure-sensitive adhesive layer can be formed by irradiating the composition with active energy rays such as ultraviolet rays. For ultraviolet irradiation, a high-pressure mercury lamp, a low-pressure mercury lamp, a metal halide lamp, a chemical light lamp, or the like can be used.

[0056] The pressure-sensitive adhesive layer 10 is preferably protected by a release liner until it is attached to an adherend. For example, when the film mirror laminate is shipped, the pressure-sensitive adhesive layer is protected by a release liner, and then the release liner is peeled off and the laminate is laminated with a supporting substrate to produce a mirror member.

[0057] The release liner is not particularly limited as long as it is capable of protecting the adhesive layer, and examples thereof include suitable thin sheets such as porous materials such as plastic films, paper, cloth, and nonwoven fabrics, nets, foam sheets, metal foils, and laminates thereof, with plastic films being preferred because of their excellent surface smoothness.

[0058] Examples of the plastic film include a polyethylene film, a polypropylene film, a polybutene film, a polybutadiene film, a polymethylpentene film, a polyvinyl chloride film, a vinyl chloride copolymer film, a polyethylene terephthalate film, a polybutylene terephthalate film, a polyurethane film, and an ethylene-vinyl acetate copolymer film.

[0059] The thickness of the release liner is usually 5 to 200 μm, preferably 5 to 100 μm. If necessary, the release liner can be subjected to a release and antifouling treatment using a silicone-based, fluorine-based, long-chain alkyl-based or fatty acid amide-based release agent, silica powder, or the like, or an antistatic treatment such as a coating type, kneading type, or deposition type. In particular, by appropriately subjecting the surface of the release liner to a release treatment such as a silicone treatment, a long-chain alkyl treatment, or a fluorine treatment, the releasability from the pressure-sensitive adhesive layer can be further improved.

[0060] From the viewpoint of obtaining a mirror member with excellent specularity, the surface of the release liner in contact with the pressure-sensitive adhesive layer is preferably highly smooth. For example, the surface of the release liner in contact with the pressure-sensitive adhesive layer preferably has a maximum height roughness Rz of 1000 μm or less, more preferably 900 μm or less, and even more preferably 800 μm or less. By setting the maximum height roughness Rz of the surface of the release liner that comes into contact with the adhesive layer within the above-mentioned range, the surface of the adhesive layer becomes smooth, and a film mirror laminate capable of forming a mirror member with excellent specularity can be obtained.

[0061] The maximum height roughness Rz of the surface of the release liner can be measured using a non-contact surface roughness measuring device. As the non-contact surface roughness measuring device, a surface roughness measuring device using an optical interference method is used, such as Wyko NT-9100 manufactured by Veeco or an equivalent product. The specific measurement procedure and conditions can be set according to the measurement conditions described in the Examples below, or so as to obtain results equivalent to or corresponding to those obtained according to said measurement conditions.

[0062] <Metal reflective layer> The metal reflective layer 12 in this embodiment is formed on the base film 11. The metal reflective layer 12 is preferably a layer having metallic luster. There is no particular limitation on the material forming the metal reflective layer 12, and it may contain a metal and a resin. The metal reflective layer 12 may be a metal layer. The case where the metal reflective layer 12 is a metal layer will be described.

[0063] The metal reflective layer 12 desirably has a relatively low melting point as well as sufficient brilliance. This is because the metal reflective layer 12 is preferably formed by thin film growth using sputtering. For this reason, a metal with a melting point of about 1000°C or less is suitable for the metal reflective layer 12, and it is preferable that the metal reflective layer 12 contains at least one metal selected from aluminum (Al), zinc (Zn), lead (Pb), copper (Cu), and silver (Ag), or an alloy containing the metal as a main component. In particular, it is preferable to use aluminum or an aluminum alloy for reasons of the luster and stability of the material, cost, etc. Furthermore, when an aluminum alloy is used, it is preferable that the aluminum content is 50 mass % or more.

[0064] The thickness of the metal reflective layer 12 is preferably 20 nm or more so as to exhibit sufficient brilliance, while it is preferably 100 nm or less from the viewpoint of sheet resistance and electromagnetic wave transmittance. For example, 20 nm to 100 nm is preferable, and 30 nm to 70 nm is more preferable. This thickness is suitable for forming a uniform film with good productivity, and also has a good appearance when a mirror member produced by attaching the film mirror laminate 1 to a supporting substrate is used as a mirror body.

[0065] <Optical adjustment layer> The film mirror laminate 1 according to the embodiment of the present invention includes an optical adjustment layer 13 on the surface of the metal reflective layer 12 opposite to the substrate film 11 . The film mirror laminate 1 according to the embodiment of the present invention has an optical adjustment layer 13, which makes the hue of the reflected light neutral, allowing an image from a light source to be projected without any color change. The optical adjustment layer 13 according to the embodiment of the present invention preferably includes at least one high refractive index layer having a refractive index of 1.75 or more. By including the high refractive index layer as the optical adjustment layer, it is possible to adjust the reflection spectrum and increase the reflectance within the visible light region. In this specification, unless otherwise specified, the "refractive index" refers to a value measured in accordance with the provisions of JIS K0062:1992 at a temperature of 25°C using light with a wavelength λ of 550 nm.

[0066] (High refractive index layer) The high refractive index layer preferably included in the optical adjustment layer according to the embodiment of the present invention is a layer having a refractive index of 1.75 or more, more preferably 1.75 to 3.2, and even more preferably in the range of 1.80 to 2.40. When a plurality of high refractive index layers are provided, the refractive indexes of the high refractive index layers may be the same or different.

[0067] The high refractive index layer is preferably a layer made of a metal oxide and / or a metal nitride. The metal elements contained in the metal oxide and metal nitride referred to here include metalloid elements such as Si. The metal oxide and / or metal nitride include metal oxynitrides. The metal oxide may be an oxide of a single metal element (single oxide) or an oxide of multiple metal elements (composite oxide). Similarly, the metal nitride may be a nitride of a single metal element (single nitride) or a nitride of multiple metal elements (composite nitride). Examples of metal elements include Ce, Nb, Si, Sb, Ti, Ta, Zr, and Zn.

[0068] More specifically, examples of materials for the high refractive index layer include CeO2 (2.30), NbO (2.33), Nb2O3 (2.15), Nb2O5 (2.32), SiN (2.03), Sb2O3 (2.10), TiO2 (2.35), Ta2O5 (2.10), ZrO2 (2.05), ZnO (2.10), ZnS (2.30), tin-doped indium oxide (ITO), antimony-doped tin oxide (ATO), and the like (the numbers in parentheses for each of the above materials are the refractive index). In particular, the high refractive index layer preferably contains at least one selected from Nb, Si, and Ti, and for example, NbO x , SiN x , TiO xIt is preferable that the material contains at least one selected from the following: NbO x It is more preferable that the material contains niobium oxide.

[0069] From the viewpoint of improving the reflectance in the visible light region, the thickness of the high refractive index layer 13b is preferably 10 nm or more, more preferably 20 nm or more, and even more preferably 30 nm or more. Also, from the viewpoint of improving the reflectance in the visible light region, the thickness is preferably 100 nm or less, more preferably 80 nm or less, and even more preferably 70 nm or less.

[0070] The optical adjustment layer may be a laminate of layers having different refractive indices, and may include a low refractive index layer in addition to a high refractive index layer. As shown in Figure 2, the film mirror laminate 1 of an embodiment of the present invention has an adhesive layer 10, a base film 11, a metal reflective layer 12 and an optical adjustment layer 13 in this order, and the optical adjustment layer 13 may be a laminate of a first low refractive index layer 13a, a high refractive index layer 13b and a second low refractive index layer 13c.

[0071] (Low refractive index layer) The low refractive index layer is a layer having a refractive index lower than that of the high refractive index layer, and the refractive index is, for example, 1.35 to 1.55, preferably 1.40 to 1.50. One or more low refractive index layers may be provided, and when more than one low refractive index layer is provided, the refractive indexes of the low refractive index layers may be the same or different. For example, the optical adjustment layer may include two low refractive index layers, a first low refractive index layer and a second low refractive index layer, and the refractive index of the first low refractive index layer may be the same as or different from that of the second low refractive index layer.

[0072] Materials for the low refractive index layer include, for example, metal oxides and metal fluorides. The metal elements contained in the metal oxides and metal fluorides referred to here include metalloid elements such as Si. The metal oxides and / or metal fluorides include metal oxyfluorides. The metal oxides may be oxides of a single metal element (single oxides) or oxides of multiple metal elements (complex oxides). Similarly, the metal fluorides may be fluorides of a single metal element (single fluorides) or fluorides of multiple metal elements (complex fluorides). Examples of the metal element include Si and Mg.

[0073] A specific example of the metal oxide is silicon oxide (SiO2: refractive index 1.46). A specific example of the metal fluoride is magnesium fluoride and fluorosilicic acid. The materials of the first low refractive index layer and the second low refractive index layer are preferably magnesium fluoride and fluorosilicic acid from the viewpoint of refractive index, and silicon oxide from the viewpoints of ease of manufacture, mechanical strength, moisture resistance, etc., and silicon oxide is preferable when various characteristics are taken into consideration comprehensively. When a plurality of low refractive index layers are provided, the materials of the low refractive index layers may be the same or different, but it is preferable that all of the low refractive index layers contain silicon oxide.

[0074] The thickness of the first low refractive index layer 13a is preferably 10 nm or more, more preferably 20 nm or more, and even more preferably 30 nm or more from the viewpoint of improving the reflectance in the visible light region, and is preferably 200 nm or less, more preferably 150 nm or less, and even more preferably 100 nm or less from the viewpoint of improving the reflectance in the visible light region.

[0075] From the viewpoint of improving the reflectance in the visible light region, the thickness of the second low refractive index layer 13c is preferably 5 nm or more, more preferably 10 nm or more, and is preferably 50 nm or less, more preferably 30 nm or less, and even more preferably 20 nm or less.

[0076] The film mirror laminate 1 may further include a layer made of, for example, titanium oxide or a mixture of the above-mentioned low refractive index material and high refractive index material (such as a mixture of titanium oxide and silicon oxide) as a medium refractive index layer having a refractive index of about 1.50 to 1.85. Examples of the optical adjustment layer include, from the metal reflective layer 12 side, the above-mentioned three-layer structure of a first low refractive index layer, a high refractive index layer, and a second low refractive index layer; a four-layer structure of a high refractive index layer, a first low refractive index layer, a high refractive index layer, and a second low refractive index layer; and a five-layer structure of a first low refractive index layer, a high refractive index layer, a medium refractive index layer, a high refractive index layer, and a second low refractive index layer. The optical adjustment layer may also be a laminate of six or more thin layers.

[0077] The film mirror laminate 1 may include a plurality of optical adjustment layers 13 . For example, some oxides, such as niobium oxide, are reduced when exposed to ultraviolet light while laminated with an adhesive, and in order to prevent the reduction reaction, a layer of silicon oxide may be further laminated as a protective layer.

[0078] The film mirror laminate according to the embodiment of the present invention may include other layers in addition to the pressure-sensitive adhesive layer, the base film, the metal reflective layer, and the optical adjustment layer depending on the application. Examples of the other layers include a surface protective coating layer, a clear hard coating layer, an easy-adhesion layer, an anti-reflection layer, a light extraction layer, and an anti-glare layer.

[0079] [Manufacturing of film mirror laminates] The method for producing the film mirror laminate according to the embodiment of the present invention is not particularly limited. For example, a metal reflective layer 12 can be formed on one side of a base film 11, and an optical adjustment layer 13 can be formed on the metal reflective layer 12. The adhesive layer 10 can be formed directly on the other side of the base film 11 by coating a composition capable of forming the adhesive layer 10, or by laminating a separately formed adhesive layer 10.

[0080] The method for forming the metal reflective layer 12 and the optical adjustment layer 13 is not particularly limited, but examples thereof include vacuum deposition, sputtering, ion plating, etc. The sputtering method is preferred because it allows strict control of the thickness even over a large area.

[0081] The film mirror laminate according to the embodiment of the present invention can be used as a mirror member. In addition, the film mirror laminate of the present embodiment can also be used for decorating a member. For example, it can be attached to a member to be attached, and the member to be attached can be, for example, a member made of glass or plastic, but is not limited thereto.

[0082] [Mirror material] The mirror member according to an embodiment of the present invention comprises the above-mentioned film mirror laminate and a supporting substrate made of a resin, and the film mirror laminate is attached to the supporting substrate via the pressure-sensitive adhesive layer. Fig. 3 is a schematic cross-sectional view of a mirror member according to one embodiment of the present invention. In the mirror member 100 shown in Fig. 3, the surface of the adhesive layer 10 in a film mirror laminate having an adhesive layer 10, a base film 11, a metal reflective layer 12, and an optical adjustment layer 13 in this order is attached to a support base 21. When a sample of the film mirror laminate in which the surface of the adhesive layer in the film mirror laminate is attached to a glass plate is irradiated with light from the optical adjustment layer side at an incident angle of 60°, the reflection image clarity at an optical comb width of 0.125 mm is 60% or more.

[0083] [Manufacture of mirror components] The method for manufacturing the mirror member according to this embodiment is not particularly limited, but the mirror member may be a mirror member in which the above-mentioned film mirror laminate and a supporting substrate in the mirror member are laminated by film insert molding. The mirror member may be a mirror member in which the above-mentioned film mirror laminate and a supporting substrate of the mirror member are laminated together by lamination. A method for manufacturing the mirror member will now be described.

[0084] In the mirror member according to the embodiment of the present invention, since the film mirror laminate is in the form of a film, it can be attached to a supporting substrate and can be produced with good productivity.

[0085] (Supporting base material) The material of the support substrate of the mirror member according to one embodiment of the present invention is not particularly limited, and examples thereof include resin, glass, metal, etc. From the viewpoint of processability and moisture content of the support substrate, it is preferable to use a resin. Examples of the resin include polyester resins such as polyethylene terephthalate (PET), polybutylene terephthalate, and polyethylene naphthalate, (meth)acrylic resins (acrylic resins and / or methacrylic resins) such as polymethacrylate, olefin resins such as polyethylene, polypropylene, and cycloolefin polymers (for example, norbornene-based, cyclopentadiene-based), and polycarbonate resins, polyethersulfone resins, polyarylate resins, melamine resins, polyamide resins, polyimide resins, cellulose resins, and polystyrene resins. These materials can be used alone or in combination of two or more. Among them, polycarbonate resins are preferable from the viewpoint of processability and heat resistance.

[0086] [Uses of film mirror laminates and mirror components] Examples of applications of the film mirror laminate and mirror member of this embodiment include structural parts for vehicles, vehicle-mounted products such as head-up displays, housings for electronic devices, housings for home appliances, structural parts, machine parts, various automobile parts, electronic device parts, household goods applications such as furniture and kitchenware, medical equipment, building material parts, other structural parts and exterior parts, etc. More specifically, in relation to vehicles, examples of the applications include instrument panels, console boxes, doorknobs, door trim, shift levers, pedals, glove boxes, bumpers, bonnets, fenders, trunks, doors, roofs, pillars, seats, steering wheels, ECU boxes, electrical parts, engine peripheral parts, drive system / gear peripheral parts, intake / exhaust system parts, cooling system parts, etc. More specific examples of electronic devices and home appliances include home appliances such as refrigerators, washing machines, vacuum cleaners, microwave ovens, air conditioners, lighting equipment, electric water heaters, televisions, clocks, ventilation fans, projectors, and speakers, as well as electronic information devices such as personal computers, mobile phones, smartphones, digital cameras, tablet PCs, portable music players, portable game consoles, chargers, and batteries. Among the above, it can be suitably used as a mirror member for a head-up display. EXAMPLES

[0087] The present invention will be described below based on examples, but the present invention is not limited to these.

[0088] <Production of film mirror laminate and mirror member> [Preparation of metal reflective layer] A PET film lumirror (hereinafter referred to as film substrate) manufactured by Toray Industries, Inc. was prepared as the substrate film. An Al target was set in a magnetron sputtering device, and an aluminum layer (Al layer) with a thickness of 44 nm was formed as a metal reflective layer on one side of the film substrate.

[0089] (Al layer formation conditions) Ultimate vacuum: 1.0×10 -4 Pa Sputtering gas: Ar Chamber pressure: 0.30Pa Base material temperature: 25℃

[0090] [Preparation of optical adjustment layer] The film substrate with the Al layer formed was set in a magnetron sputtering device, and a thin transparent oxide film was formed on the Al layer in the following order to form an optical adjustment layer: silicon oxide 67 nm (refractive index 1.46), niobium oxide (Nb2O5) 53 nm (refractive index 2.32), and silicon oxide (SiO2) 20 nm. In forming the silicon oxide and niobium oxide thin films, a pure silicon target and a pure niobium target were used as targets, and oxygen gas was introduced in addition to argon gas to perform reactive sputtering to obtain thin transparent oxide films.

[0091] (Silicon oxide film formation conditions) Ultimate vacuum: 1.0×10 -4 Pa Sputtering gas: Ar and O2 are used, and O2 / (Ar+O2) is adjusted to 0.3. Chamber pressure: 0.30Pa Base material temperature: 25℃

[0092] (Niobium oxide film formation conditions) Ultimate vacuum: 1.0×10 -4 Pa Sputtering gas: Ar and O2 are used, and O2 / (Ar+O2) is adjusted to 0.1. Chamber pressure: 0.30Pa Base material temperature: 25℃

[0093] As a result, laminate 1 was produced in which thin layers of aluminum 44 nm, silicon oxide 67 nm, niobium oxide 53 nm, and silicon oxide 20 nm were formed in this order on one side of a 50 μm PET substrate.

[0094] Example 1 As an adhesive layer, a light release liner (Rz on the adhesive layer side: 759 μm) of a 25 μm thick adhesive sheet (CS9861F, manufactured by Nitto Denko Corporation) was peeled off and bonded to the side of the base film of Laminate 1 that had not been sputtered to produce a film mirror laminate. The heavy release liner on the adhesive layer side of the film mirror laminate was peeled off (Rz on the adhesive layer side: 833 μm), and the laminate was attached to a 1.2 to 1.5 mm thick glass plate (S200200 manufactured by Matsunami Glass Industry Co., Ltd.) as a supporting substrate to prepare a mirror member. The test piece size was 50 mm × 150 mm.

[0095] Comparative Example 1 A film mirror laminate and a mirror member were prepared in the same manner as in Example 1, except that the adhesive sheet was changed to an adhesive sheet (CS9861UAS, manufactured by Nitto Denko Corporation) with an Rz of 1196 μm on the adhesive layer side of the light release liner, an Rz of 1044 μm on the adhesive layer side of the heavy release liner, and a thickness of 25 μm.

[0096] <60° Reflection Image Clarity (%)> The film mirror laminates produced in the Examples and Comparative Examples were attached with the pressure-sensitive adhesive layer 10 side to a glass plate to prepare samples. In accordance with JIS K7374 (Plastics - Determination of image clarity), the 60° reflection image clarity was measured under optical conditions of an incident angle of 60° and a receiving angle of 60° using an image clarity measuring instrument ICM-1T (manufactured by Suga Test Instruments Co., Ltd.). The light from the light source was passed through a light source slit with a width of 0.03 mm and collimated using a lens, the light source image was irradiated from the optical adjustment layer 13 side of the sample, and the reflected image was formed on the optical comb and received by a receiver for measurement. The optical comb had a width ratio of the light-shielding part to the light-transmitting part (slit) of 1:1, and the slit widths were arranged in order of 0.125 mm, 0.25 mm, 0.5 mm, 1.0 mm, and 2.0 mm (optical comb widths (optical comb widths) 0.125 mm, 0.25 mm, 0.5 mm, 1.0 mm, and 2.0 mm), and the slit widths moved continuously from the wide side through the narrow side to the dark part, and the image was repeatedly transmitted and shielded and received. The largest value among the light receiving amounts obtained by the receiver is the maximum light receiving amount Mn The smallest value is the minimum light receiving amount m n Then, the image clarity (image clarity) C is calculated by the following formula (1). n (%) was calculated and used as the 60° reflection image clarity.

[0097]

number

[0098] <Release liner Rz> The maximum height roughness Rz (μm) was measured for the surface of the release liner used in the Examples and Comparative Examples that was in contact with the pressure-sensitive adhesive layer. The measurements were performed using a scanning white light interferometer "Zygo NewView7300" (manufactured by ZYGO) under the following conditions. [Measurement conditions] Objective lens: 10x Zoom lens: 1x Remove: Cylinder

[0099] <Unevenness evaluation> The unevenness values ​​were measured for the mirror members produced in the examples and comparative examples. First, the prepared mirror member was used as an evaluation sample, and was placed with its optical adjustment layer side facing the light source, so that the angle with respect to the light from the light source was about 45 degrees. A white screen was placed at the end of the light beam, and the reflected image was projected onto it. As the light source, a "mercury xenon lamp" manufactured by Hamamatsu Photonics K.K. was used. The light source, evaluation sample, and screen were placed so that the distance between the evaluation sample and the light source, and the distance between the evaluation sample and the screen were each about 50 cm. The unevenness value is a value obtained by turning on the light source, capturing an image reflected by the sample and projected onto the screen with an EyeScale-4W camera, and reading the captured image in ISC-S mode. A value of 20 or less is considered good.

[0100] The measurement results and evaluation results for each of the examples and comparative examples are shown in Table 1 below.

[0101] [Table 1]

[0102] As described above, the mirror member using the film mirror laminate of this embodiment had a 60° reflection image clarity of 60% or more on a 0.125 mm wide optical comb, resulting in a low unevenness value and excellent mirror surface, and therefore the film mirror laminate of this embodiment was suitable for use as a mirror member. In addition, the film mirror laminate of this embodiment can be attached to a supporting substrate via an adhesive layer, making it possible to obtain a mirror member with good productivity and easily adaptable to complex curved surface shapes, etc.

[0103] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present invention. [Explanation of symbols]

[0104] 1. Film mirror laminate 10 Adhesive layer 11 Base film 12 Metal reflective layer 13 Optical adjustment layer 13a First low refractive index layer 13b High refractive index layer 13c Second low refractive index layer 21 Supporting base material 100 Mirror material

Claims

1. A film mirror laminate having a pressure-sensitive adhesive layer, a substrate film, a metal reflective layer, and an optical adjustment layer in this order, A film mirror laminate, in which a reflection image clarity at an optical comb width of 0.125 mm is 60% or more when light is incident on a sample in which the surface of the adhesive layer in the film mirror laminate is attached to a glass plate from the optical adjustment layer side at an incident angle of 60°.

2. The film mirror laminate according to claim 1 , wherein the optical adjustment layer comprises a low refractive index layer and a high refractive index layer.

3. The film mirror laminate according to claim 2 , wherein the low refractive index layer contains silicon oxide.

4. The film mirror laminate according to claim 2 , wherein the high refractive index layer contains niobium oxide.

5. The film mirror laminate according to claim 1, wherein the metal reflective layer comprises at least one metal selected from aluminum (Al), zinc (Zn), lead (Pb), copper (Cu), and silver (Ag), and an alloy mainly composed of the metal.

6. A mirror member comprising the film mirror laminate according to any one of claims 1 to 5 and a supporting substrate, the surface of the film mirror laminate on the side of the pressure-sensitive adhesive layer being attached to the supporting substrate.

Images