Anti-reflective film, method of use thereof, and plastic molded product using the same

Abstract

To provide an antireflection hard coat film for molding having: a high coefficient of expansion and sufficient moldability before being photo-cured; and furthermore having low reflectance and high scratch resistance after being photo-cured and stable and low surface tackiness before being photo-cured.SOLUTION: An antireflection hard coat film for molding is provided in which a hard coat layer and a low refractive index layer are laminated in this order on a substrate film having optical transparency, wherein the hard coat layer includes a (meth) acrylic polymer, a compound having a polymerizable functional group and a photoinitiator, wherein the compounding ratio of the acrylic polymer is 40-60 wt.% with respect to the total solid content, and a compounding ratio of the photoinitiator is 0.1-5.0 pts.wt. with respect to 100 pts.wt. of a photopolymerizable component.SELECTED DRAWING: None

Description

[Technical Field]

[0001] This invention relates to an anti-reflective film with excellent moldability, a method of using the same, and a plastic molded product using the same. [Background technology]

[0002] Acrylic photocurable resins are used in many fields to impart special properties to the surfaces of plastic films and molded plastic products. For example, hard coat films, which are applied to PET (polyethylene terephthalate) films to impart high hardness, are widely used as touch panel films and molding films.

[0003] Among these, insert films are particularly well known for molding, in which a pattern is printed on the film surface and then three-dimensionally molded after being softened by heating. However, hardening the hard coat resin layer applied to the film makes it prone to microcracks on curved surfaces when processing into a three-dimensional shape, thus limiting the processing shape. For this reason, an after-cure method has been devised in which the hard coat layer is not fully cured before three-dimensional molding, but is photocured after molding. In the past, the applicant has also invented a resin composition containing a polyfunctional polymerizable compound having two or more acryloyl groups, a low molecular weight amine with a molecular weight of 50 to 400, and a polyamine with a molecular weight of 1 to 200,000 (Patent Document 1).

[0004] This hard coat resin composition was excellent because it could produce a hard coat film with high hardness and scratch resistance, as well as good moldability. However, in recent years, there has been a demand for anti-reflective properties on the film surface, and there has been a need for an after-cure anti-reflective film for molding that has high elongation and sufficient moldability before photocuring, is tackless, and also has an anti-reflective layer. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Patent No. 5654207 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] The object of the present invention is to provide a moldable anti-reflective film that has a high elongation rate and sufficient moldability before photocuring, while having low reflectivity and high scratch resistance after photocuring, and having a consistently low surface tack before photocuring, as well as a method of using the same and a plastic molded product using the same. [Means for solving the problem]

[0007] To solve the above problems, the invention of claim 1 is characterized in which a hard coat layer formed by curing a hard coat resin composition and a low refractive index layer formed by curing a low refractive index resin composition are laminated in this order on a light-transmitting substrate film, wherein the hard coat resin composition comprises a (meth)acrylic polymer (A1), a compound having polymerizable functional groups (B), and a photopolymerization initiator (C), wherein the blending ratio of (A1) is 40 to 60% by weight of the total solid content, and the blending amount of (C) is 0.1 to 5.0 parts by weight per 100 parts by weight of (B), and the low refractive index resin composition comprises a (meth)acrylic polymer (A2) having polymerizable functional groups. Furthermore, the amount of (A2) mentioned above is 5 to 40% by weight relative to the total amount of solids. Anti-reflective film characterized by Manufacturing method To provide.

[0008] Furthermore, the invention of claim 2 is that the amount of (A2) added is 5 to the total amount of solids of the low refractive index resin composition. 35% by weight The anti-reflective film according to claim 1, characterized in that it is Manufacturing method To provide.

[0009] Furthermore, the invention of claim 3 is characterized in that (A2) is a (meth)acrylic polymer obtained by reacting a portion of the carboxyl groups of a (meth)acrylic copolymer having carboxyl groups in its side chains with an alicyclic epoxy (meth)acrylate, and is the anti-reflective film according to claim 1 or 2. Manufacturing method To provide.

[0010] Furthermore, the invention of claim 4 is, An anti-reflective film is provided, wherein a hard coat layer formed by curing a hard coat resin composition and a low refractive index layer formed by curing a low refractive index resin composition are laminated in this order on a light-transmitting substrate film, the hard coat resin composition comprises a (meth)acrylic polymer (A1), a compound having polymerizable functional groups (B), and a photopolymerization initiator (C), the blending ratio of (A1) is 40 to 60% by weight of the total solid content, and the blending amount of (C) is 0.1 to 5.0 parts by weight per 100 parts by weight of (B), and the low refractive index resin composition comprises a (meth)acrylic polymer (A2) having polymerizable functional groups, and the method for producing an anti-reflective film is characterized by forming a hard coat layer that is partially cured by ultraviolet irradiation when curing the hard coat resin composition, applying the low refractive index resin composition thereon and drying it, and then secondary curing it by ultraviolet irradiation. To provide.

[0011] Furthermore, the invention of claim 5 is, The method for producing an anti-reflective film according to claim 4, characterized in that the amount of (A2) is 5 to 40% by weight relative to the total amount of solids in the low refractive index resin composition. To provide.

[0012] Furthermore, the invention of claim 6 is, The method for producing an anti-reflective film according to either claim 4 or 5, characterized in that (A2) is a (meth)acrylic polymer obtained by reacting a portion of the carboxyl groups of a (meth)acrylic copolymer having carboxyl groups in its side chains with an alicyclic epoxy (meth)acrylate. To provide. [Effects of the Invention]

[0013] The anti-reflective film of the present invention is useful as an after-curing type anti-reflective film for molding because it has a high elongation rate and sufficient moldability before photocuring, while having low reflectivity and high scratch resistance after photocuring, and also has a consistently low surface tack before photocuring. [Best Mode for Carrying Out the Invention]

[0014] The anti-reflective film of the present invention can be manufactured using two types of resin compositions: an HC resin composition for forming a hard coat (hereinafter referred to as HC) layer and an LR resin composition for forming a low refractive index (hereinafter referred to as LR) layer. The HC resin composition is preferably a composition comprising a (meth)acrylic polymer (A1), a compound having polymerizable functional groups (B), and a photopolymerization initiator (C). The LR resin composition is preferably a composition comprising a (meth)acrylic polymer (A2) having polymerizable functional groups, a photopolymerization initiator (C), hollow nanosilica (D), and a surface modifier (E). In this specification, (meth)acrylate encompasses both acrylate and methacrylate.

[0015] The (meth)acrylic polymer (A1) used in the HC resin composition of the present invention is blended for the purpose of improving the elongation rate in the semi-cured state by ultraviolet irradiation. As the monomers constituting (A1), it is preferable to include an alkyl (meth)acrylate having 1 to 8 carbon atoms in the alkyl group from the viewpoints of coating properties and elongation rate, and it is more preferable to include methyl methacrylate (hereinafter referred to as MMA) and butyl acrylate.

[0016] The polymerization method of the above (A1) is not particularly limited, and known methods can be used. For example, solution polymerization, emulsion polymerization, bulk polymerization, etc. can be mentioned. Among these, solution polymerization in which the polymer is obtained as a solution is preferable. Specifically, a monomer and a solvent are mixed, a known polymerization initiator and a chain transfer agent are added, and polymerization can be carried out by heating. The polymerization temperature is preferably 70 to 130°C, and more preferably 80 to 120°C.

[0017] The weight average molecular weight (hereinafter referred to as Mw) of the above (A1) is preferably 30,000 to 200,000, and more preferably 50,000 to 150,000. By setting it to 30,000 or more, a sufficient elongation rate can be ensured, and by setting it to 200,000 or less, it becomes easy to adjust to a viscosity with good workability. Note that Mw was measured and calculated by gel permeation chromatography using a column filled with a styrene divinylbenzene substrate and a tetrahydrofuran eluent to obtain the molecular weight in terms of standard polystyrene.

[0018] The blending ratio of the above (A1) is 40 to 60% by weight based on the total solid content contained in the HC resin composition, and preferably 42 to 58% by weight. If it is less than 40% by weight, the elongation rate at the semi-cured point is not sufficient and the moldability tends to be poor. If it exceeds 60% by weight, the coating appearance deteriorates and the reflectance also tends to increase.

[0019] The (meth)acrylic polymer (A2) used in the LR resin composition of the present invention is a major component of the binder resin and has polymerizable functional groups. Examples of polymerizable functional groups include (meth)acryloyl groups, (meth)allyl groups, vinyl groups, maleimide groups, epoxy groups, etc., but (meth)acryloyl groups are preferred because they exhibit excellent curability when irradiated with light such as ultraviolet light.

[0020] Of the above (A2), a (meth)acrylic polymer obtained by reacting a portion of the carboxyl groups of a (meth)acrylic copolymer having carboxyl groups in its side chains with an alicyclic epoxy (meth)acrylate is preferred because it can make the surface of the coating film tack-free after solvent drying, has little hue change, and has excellent heat resistance and weather resistance.

[0021] The Mw of (A2) is preferably 5,000 to 30,000, and more preferably 7,000 to 25,000. Setting it to 5,000 or higher ensures sufficient coating strength, while setting it to 50,000 or lower ensures good solubility in the solvent and a satisfactory coating appearance. The acid value (KOH mg / g) is preferably 20 to 200, and more preferably 50 to 100. Setting it to 20 or higher ensures sufficient adhesion to the substrate, while setting it to 200 or lower ensures compatibility when used in combination with other polymerizable functional groups (B).

[0022] The blending ratio of (A2) is preferably 5 to 40% by weight, and more preferably 8 to 35% by weight, relative to the total amount of solids contained in the LR resin composition. A blending ratio of 5% by weight or more ensures sufficient elongation, and a blending ratio of 40% by weight or less ensures a sufficiently low refractive index. Furthermore, when compound (B) having other polymerizable functional groups is included, the blending ratio of (A2) is preferably 70% by weight or more, and more preferably 90% by weight or more, relative to the total amount of binder resin components of (A2) and (B). A blending ratio of 70% by weight or more ensures sufficient tacklessness and allows for stable productivity in the molding process before light irradiation.

[0023] In HC resin compositions and LR resin compositions, compound (B) having polymerizable functional groups used in addition to (A1) and (A2) includes oligomers such as urethane (meth)acrylate (hereinafter referred to as urea), epoxy (meth)acrylate, polyester (meth)acrylate, polycarbonate (meth)acrylate, and diene (meth)acrylate, which can be used alone or in combination of two or more. Among these, urea is preferred because it has a good balance of reactivity, abrasion resistance, and weather resistance, and excellent compatibility with (A1) and (A2). In terms of the number of functional groups, four or more functional groups are preferred in terms of curability, and examples include a hexafunctional urea obtained by reacting hexamethylene diisocyanate (hereinafter referred to as HDI) and pentaerythritol triacrylate (hereinafter referred to as PETA).

[0024] As for (B) above, a low molecular weight binder may be used as a component other than the oligomer. Examples include (meth)acrylates having functional groups such as aliphatic, alicyclic, polyether skeletons, hydroxyl groups, and amino groups, and acrylamide compounds, which can be used alone or in combination of two or more. In terms of the number of functional groups, four or more functional groups are preferable from the standpoint of curability, and examples include pentaerythritol tetraacrylate, dipentaerythritol tetraacrylate, dipentaerythritol pentaacrylate, and dipentaerythritol hexaacrylate (hereinafter referred to as DPHA).

[0025] The photopolymerization initiator (C) used in this invention generates radicals upon irradiation with ultraviolet light or electron beams, and these radicals trigger the polymerization reaction. General-purpose photopolymerization initiators such as benzyl ketal, acetophenone, and phosphine oxide can be used. By arbitrarily selecting the light absorption wavelength of the polymerization initiator, curability can be imparted over a wide wavelength range from the ultraviolet region to the visible light region. Specifically, examples include 2,2-dimethoxy-1,2-diphenylethane-1-one as a benzyl ketal, 1-hydroxycyclohexyl-phenyl-ketone and 1-[4-(2-hydroxyethoxy)-phenyl]-2-hydroxy-2-methyl-1-propane-1-one as α-hydroxyacetophenones, 2-methyl-1-(4-methylthiophenyl)-2-morpholinopropane-1-one as an α-aminoacetophenone, and 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide and bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide as acylphosphine oxides, which can be used individually or in combination of two or more.

[0026] In the case of HC resin compositions, (C) preferably contains an α-hydroxyacetophenone-based compound that is less prone to yellowing. Examples of commercially available products include Omnirad2959, Omnirad127D, and Omnirad184 (product name: manufactured by IGM Resins). Among these, Omnirad2959 is particularly preferred because it exhibits less yellowing and excellent scratch resistance.

[0027] The amount of photopolymerization component in the HC resin composition of (C) described above is 0.1 to 5.0 parts by weight per 100 parts by weight, preferably 0.5 to 4.5 parts by weight, and more preferably 0.8 to 4.0 parts by weight. If the amount is less than 0.1 parts by weight, it may not cure sufficiently, and if it exceeds 5.0 parts by weight, the elongation in the semi-cured state tends to be insufficient, resulting in poor moldability.

[0028] In the case of an LR resin composition, (C) preferably contains an α-hydroxyacetophenone system, similar to the case of an HC resin composition, and Omnirad127D, which has excellent curability in thin films, is particularly preferred. The amount of (C) added to 100 parts by weight of the photopolymerization component in the LR resin composition is preferably 5 to 35 parts by weight, and more preferably 8 to 15 parts by weight.

[0029] In this invention, it is preferable to incorporate hollow nanosilica (D) to lower the refractive index of the LR resin composition. (D) is a silica particle that has a cavity containing air with a refractive index of 1, and has the function of lowering the refractive index while maintaining the coating strength of the LR layer. While the refractive index of solid silica particles is about 1.45, the refractive index of (D) decreases as the occupancy rate of the internal cavity increases, and is about 1.20 to 1.40.

[0030] The primary particle diameter of (D) is preferably 5 to 150 nm, more preferably 10 to 100 nm, and particularly preferably 40 to 80 nm. By setting it within this range, good dispersibility can be obtained without impairing the transparency of the LR layer. In particular, if it is 40 to 80 nm, it is possible to increase the cavity occupancy and lower the refractive index while ensuring an outer shell thickness that does not result in insufficient strength. A commercially available product is Thru-Ria 4320 (product name: manufactured by JGC Catalysts & Chemicals, primary average particle diameter 60 nm).

[0031] The amount of the LR resin composition (D) in relation to the total solid content is preferably 45 to 80% by weight, and more preferably 50 to 78% by weight. A concentration of 45% by weight or more allows for a sufficient reduction in refractive index, while a concentration of 80% by weight or less ensures sufficient adhesion to the underlying hard coat layer.

[0032] In the present invention, it is preferable to incorporate a surface modifier (E) to enhance the water- and oil-repellent properties of the LR resin composition and improve its stain resistance. Examples include silicone-based, fluorine-based, and acrylic-based modifiers, but it is preferable to have a reactive functional group that can polymerize with the binder resin to form a cured coating film, as this prevents the coating from being removed over time due to bleeding or other reasons after curing and allows the effect to be sustained for a long period of time. Fluorine-based compounds are particularly preferable because their low surface free energy makes them prone to segregation on the coating surface after application, allowing for long-term stabilization of abrasion resistance and stain resistance.

[0033] The blending ratio of (E) to the total amount of solids is preferably 8 to 20% by weight, and more preferably 10 to 15% by weight. A ratio of 8% by weight or more ensures sufficient water and oil repellency, while a ratio of 20% by weight or less ensures a satisfactory coating appearance.

[0034] The composition of the present invention may optionally contain ultraviolet absorbers, antioxidants, adhesion promoters, bluing agents, defoaming agents, thickeners, anti-precipitation agents, antistatic agents, anti-fogging agents, antibacterial agents, organic fine particles, etc., to the extent that it does not impair performance. The HC resin composition may also contain small amounts of curing components such as amines and isocyanates.

[0035] When applying the HC resin composition and the LR resin composition (hereinafter collectively referred to as the resin compositions of this application), they may be diluted with solvents such as toluene, isobutanol, ethyl acetate, butyl acetate, hexane, cyclohexane, cyclohexanone, methylcyclohexanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, and propylene glycol monomethyl ether (hereinafter referred to as PGM) to improve coating properties. While a solid content of 1-50% is exemplified for dilution, there is no specific requirement, and it can be appropriately set to achieve a viscosity that facilitates coating.

[0036] Examples of substrate films to which the HC resin composition is applied include polyester film, triacetylcellulose film, polycarbonate (hereinafter referred to as PC) film, polysulfone film, nylon film, cycloolefin film, acrylic (hereinafter referred to as PMMA) film, polyimide film, ABS film, polyolefin film, PVC film, and PVA film. Among these, biaxially oriented polyester film is preferred in terms of weather resistance, processability, and dimensional stability. Furthermore, PMMA film and PC film are preferred for automotive interior decoration, and laminated films thereof may also be used. The film thickness should generally be between 25 μm and 500 μm.

[0037] The aforementioned base film can be subjected to surface treatments such as primer treatment, sandblasting, solvent treatment to create surface irregularities, or corona discharge treatment, chromic acid treatment, or ozone / ultraviolet irradiation treatment to improve adhesion with the resin composition of the present invention.

[0038] The method of applying the resin composition of this invention is not particularly limited, and it can be formed by known coating methods such as spray coating, roll coating, die coating, air knife coating, blade coating, spin coating, reverse coating, gravure coating, and wire bar coating, or by printing methods such as gravure printing, screen printing, offset printing, and inkjet printing.

[0039] The film thickness of the HC resin composition can be exemplified as 1 μm to 10 μm when dry, but is not limited to this. Furthermore, the film thickness of the LR resin composition coated on the HC layer is preferably 50 to 200 nm when dry, and more preferably 80 to 150 nm. If the thickness of the LR layer is within this range, it is possible to sufficiently lower the reflectance.

[0040] The light source for ultraviolet irradiation used when curing the resin composition of this invention may be a low-pressure mercury lamp, a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a carbon arc lamp, a xenon lamp, a metal halide lamp, an LED lamp, or an electrodeless ultraviolet lamp. The irradiation atmosphere may be air or an inert gas such as nitrogen or argon. Furthermore, curing properties can be improved by heating the back roll or the coating film with an IR heater during ultraviolet irradiation.

[0041] The irradiation conditions were an irradiation intensity of 500 mW / cm². 2 ~3000mW / cm 2 Exposure dose: 50-400 mJ / cm² 2 Examples are given, but the invention is not limited to these. As for the method of ultraviolet irradiation, it is preferable to first partially cure the HC layer with a low exposure dose, then apply the LR resin composition on top of it and dry it, further mold it into a three-dimensional shape, and finally perform secondary curing by ultraviolet irradiation.

[0042] By partially curing the HC layer, when an LR resin composition with low solid content is applied, the dissolution of the binder resin component in the HC layer by the solvent can be reduced, which is expected to suppress the deterioration of appearance and the increase in reflectivity.

[0043] In this specification, "semi-cured" means that some of the (meth)acryloyl groups in the HC resin composition have undergone a crosslinking reaction and film formation is complete, but the HC layer has not yet undergone final curing. Since the amount of unreacted (meth)acryloyl groups changes before and after UV irradiation, the reflectance ATR measurement method using infrared spectroscopy is used, at a wavelength of 810 cm. -1 The nearby peak area (hereinafter referred to as P810) and wavelength 1720 cm -1 The peak area in the vicinity (hereinafter referred to as P1720) is measured and defined from its ratio. In the following formula (1), it is preferable that the hardening rate is 15 to 45%. Curing rate (%) = ((P810 before UV irradiation / P1720 before UV irradiation) - (P810 after UV irradiation / P1720 after UV irradiation)) / (P810 before UV irradiation / P1720 before UV irradiation)...Formula (1)

[0044] When the HC resin composition is applied to a base film and partially cured, and then the LR resin composition is applied and dried, a tensile test is performed at an ambient temperature of 130°C and a tensile speed of 300 mm / min. The elongation is preferably 50% or more, and more preferably 100% or more. An elongation of 50% or more indicates that the film has sufficient elongation characteristics as an after-curing type molded film.

[0045] The present invention will be described in detail below with reference to examples and comparative examples, but these are merely examples and the invention is not limited to them. Unless otherwise specified, measurements were taken under conditions of 25°C and 65% relative humidity, and the units in the formulation table are parts by weight, converted to solid content.

[0046] HC resin composition formulation As (A1), Z-624BA-2 (product name: manufactured by Aica Kogyo Co., Ltd., acrylic copolymer consisting of MMA and butyl methacrylate monomer, Mw 100,000), as (B), urethane acrylate (PETA-HDI-PETA skeleton) and DPHA (dipentaerythritol hexaacrylate), and as (C), Omnirad 2959 (product name: manufactured by IGM Resins, α-hydroxyacetophenone type) and Omnirad 184 (product name: manufactured by IGM Resins, α-hydroxyacetophenone type) were mixed and stirred until uniformly dissolved and dispersed in the formulations shown in Table 1. Further dilution and stirring were performed by adding PGM so that the solid content was 30%, to obtain HC resin compositions 1 to 10.

[0047] LR resin composition formulation As (A2), Cyclomer P ACA Z250 (trade name: manufactured by Daicel Ornex Co., Ltd., Mw 22,000, oxidation 70 (KOH mg / g)) was used. As (C), Omnirad 127D (trade name: manufactured by IGM Resins Co., Ltd., α-hydroxyacetophenone-based) was used. As (D), Throughia 4320 (trade name: manufactured by JGC Catalysts & Chemicals Ltd., particle diameter 60 nm, refractive index 1.3) was used. As (E), KY-1203 (trade name: manufactured by Shin-Etsu Chemical Co., Ltd., reactive fluorine-based compound) was used. Stir until uniformly dissolved and dispersed with the formulation described in Table 2. Further, add PGM to make the solid content 3% and stir for dilution to obtain the LR resin compositions 11 to 13.

[0048] Table 1 JPEG0007883841000001.jpg57151

[0049] Table 2 JPEG0007883841000002.jpg86131

[0050] The evaluation method was as follows.

[0051] HC film creation Using HC resin compositions 1 to 10, coat the PMMA surface of PMMA / PC film C003 (trade name: manufactured by Sumitomo Chemical Co., Ltd., thickness 300 μm) to a dry film thickness of 3 μm and dry at 80°C for 1 minute. Then, using a high-pressure mercury lamp, semi-cure the HC film under the conditions of an output of 300 mW / cm 2 , 25 mJ / cm 2 (curing rate 30%) to create a semi-cured HC film.

[0052] Creation of anti-reflective film On the HC film created above, apply LR resins 11 to 13 in the combinations shown in Table 3 to a dry film thickness of 100 nm, and dry at 80°C for 1 minute to create a film before secondary curing by ultraviolet light. Then, perform secondary curing using a high-pressure mercury lamp under the conditions of an output of 100 mW / cm 2 , 800 mJ / cm 2 to form an antireflection film.

[0053] Coating appearance: The appearance of the HC film after partial curing by ultraviolet light and the anti-reflective film before secondary curing by ultraviolet light was visually inspected. A ○ was given if there was no whitening or other issues and the leveling properties were good, and a × was given if there were any abnormalities in the appearance.

[0054] Tackiness: Using HC film after partial curing by UV light and anti-reflective film before secondary curing by UV light, surface tackiness was checked by touch. ○ indicated no tackiness, and × indicated tackiness.

[0055] Elongation: Using anti-reflective film before secondary curing by ultraviolet light, cut to 25mm wide x 50mm long, a tensile test was performed using a Minebea TechnoGraph TGI-1KN with a chuck distance of 50mm, an ambient temperature of 130°C, and a tensile speed of 300mm / min. Cracks were visually confirmed, and an elongation of 50% or more was marked with ○, 100% or more with ◎, and less than 50% with ×. Calculation formula: The calculation is based on how many millimeters it has grown, with 50mm as the base. Length elongated (mm) / 50mm × 100 = Elongation rate (%).

[0056] Adhesion: Using UV-cured film, a 10x10 grid was created on the coated surface at 1mm intervals according to the cross-cut method of JIS K 5600-5-6. Cellophane tape CT-24 (product name: Nichiban Co., Ltd.) was applied and pulled upwards to check the peeling condition. 100 / 100 was marked as ○, and 0 / 100 to 99 / 100 was marked as ×.

[0057] Minimum reflectance: Using a UV-cured film, the side opposite the coated surface was scratched with sandpaper, filled with a black pigment marker, and then black PET was bonded to make the reflectance of the opposite side 0%. Then, the reflectance of the HC side was plotted at 1 nm intervals in the range of 300 nm to 780 nm using a spectrophotometer, and the lowest reflectance was measured. A value of 2.0% or less was marked with ○, and a value greater than 2.0% was marked with ×.

[0058] Steel wool resistance: Using UV-cured film, a load of 100g / cm2 was placed on top of steel wool #0000 and moved back and forth 10 times. Films that did not show any damage were marked with ○, and those that did show damage were marked with ×.

[0059] Evaluation results Table 3 JPEG0007883841000003.jpg104153

[0060] The example showed no problems and was satisfactory in all evaluations, including coating appearance, tackiness, elongation, adhesion, minimum reflectivity, and steel wool resistance.

[0061] On the other hand, Comparative Example 1, in which the amount of (A1) exceeded the upper limit, had a large coating appearance and minimum reflectivity of the LR layer, while Comparative Example 2, in which the amount of (A1) was below the lower limit, had a low elongation rate. Furthermore, Comparative Example 3, which did not contain (A1), had a poor elongation rate and a strong tack in the HC layer, and Comparative Example 4, in which the amount of (C) exceeded the upper limit, also had a low elongation rate. All of these were unsuitable for the present invention.

Claims

1. A light-transmitting substrate film is laminated in the following order: a hard coat layer formed by curing a hard coat resin composition, and a low refractive index layer formed by curing a low refractive index resin composition. The hard coat resin composition comprises a (meth)acrylic polymer (A1), a compound having polymerizable functional groups (B), and a photopolymerization initiator (C), wherein the blending ratio of (A1) is 40 to 60% by weight of the total solid content, and the blending amount of (C) is 0.1 to 5.0 parts by weight per 100 parts by weight of (B). A method for producing an anti-reflective film, characterized in that the low refractive index resin composition contains a (meth)acrylic polymer (A2) having polymerizable functional groups, and the amount of (A2) blended is 5 to 40% by weight with respect to the total solid content.

2. The method for producing an anti-reflective film according to claim 1, characterized in that the amount of (A2) is 5 to 35% by weight relative to the total amount of solids in the low refractive index resin composition.

3. The method for producing an anti-reflective film according to claim 1 or 2, characterized in that (A2) is a (meth)acrylic polymer obtained by reacting a portion of the carboxyl groups of a (meth)acrylic copolymer having carboxyl groups in its side chains with an alicyclic epoxy (meth)acrylate.

4. A light-transmitting substrate film is laminated in the following order: a hard coat layer formed by curing a hard coat resin composition, and a low refractive index layer formed by curing a low refractive index resin composition. The hard coat resin composition comprises a (meth)acrylic polymer (A1), a compound having polymerizable functional groups (B), and a photopolymerization initiator (C), wherein the blending ratio of (A1) is 40 to 60% by weight of the total solid content, and the blending amount of (C) is 0.1 to 5.0 parts by weight per 100 parts by weight of (B). A method for producing an antireflective film in which the low refractive index resin composition comprises a (meth)acrylic polymer (A2) having polymerizable functional groups, characterized in that when curing the hard coat resin composition, a hard coat layer is formed by ultraviolet irradiation and partially cured, and the low refractive index resin composition is applied thereon, dried, and then secondarily cured by ultraviolet irradiation.

5. The method for producing an anti-reflective film according to claim 4, characterized in that the amount of (A2) added is 5 to 40% by weight with respect to the total amount of solids in the low refractive index resin composition.

6. The method for producing an anti-reflective film according to claim 4 or 5, characterized in that (A2) is a (meth)acrylic polymer obtained by reacting a portion of the carboxyl groups of a (meth)acrylic copolymer having carboxyl groups in its side chains with an alicyclic epoxy (meth)acrylate.

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