Optical laminate
Patent Information
- Application Number
- PCT/JP2025/007149
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-03-04
- Filing Date
- 2025-02-28
- Publication Date
- 2025-10-02
AI Technical Summary
The use of resin materials derived from biomass materials in optical laminates can result in odor generation due to impurities and residual additives, which is not effectively addressed by existing technologies.
Incorporating adsorbent particles, such as hollow and porous particles, primarily silica, into the resin substrate to adsorb odor components, maintaining high light transmittance and low haze, thereby suppressing odor generation.
The solution effectively reduces odor emission while maintaining optical properties, ensuring high light transmittance and low haze in optical laminates using biomass-derived resins.
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Figure JP2025007149_02102025_PF_FP_ABST
Abstract
Description
optical laminate
[0001] The present disclosure relates to optical laminates.
[0002] In recent years, the movement toward a sustainable society and a recycling-oriented society has been accelerating, and there is a demand for reducing the amount of petroleum-derived materials used. Accordingly, there is a demand for a technology for producing and using resin materials derived from biomass materials (see, for example, Patent Document 1).
[0003] Patent Document 1 describes a technology for producing a glycol derived from a biomass material that has excellent light transmittance, and obtaining a polyester from the glycol.
[0004] Japanese Patent Application Laid-Open No. 2009-209145
[0005] In resins derived from biomass materials, impurities may be mixed into the resin during the resin production process. Furthermore, to reduce the impact of these impurities, it may be necessary to add additives to the resin depending on the impurities expected to be mixed in. In such cases, the resin may emit an odor due to impurities or residual additives contained in the resin.
[0006] The present disclosure has been made in consideration of the above points, and aims to suppress the generation of odor while using a resin derived from a biomass material in an optical laminate.
[0007] Embodiments of the present disclosure relate to the following [1] to
[17] .
[0008] [1] An optical laminate comprising a resin substrate and a first layer, wherein the resin substrate contains a resin derived from a biomass material as a main component, the first layer contains adsorbent particles, the adsorbent particles being at least one type of particle selected from hollow particles and porous particles, and the optical laminate has a total light transmittance of 70% or more and a haze of 2.0% or less.
[0009] [2] The optical laminate according to [1], wherein the adsorptive particles are light-transmitting particles.
[0010] [3] The optical laminate according to [1] or [2], wherein the adsorptive particles contain silica or alumina.
[0011] [4] The optical laminate according to any one of [1] to [3], wherein the adsorptive particles include hollow silica particles.
[0012] [5] The optical laminate according to any one of [1] to [4], wherein the average distance between the centers of gravity of the adsorbent particles in the first layer is defined as an average La, and the average La is 90 nm or more and 130 nm or less.
[0013] [6] An optical laminate according to any one of [1] to [5], wherein the average of the distances between the centers of gravity of the adsorbent particles in the first layer is the average La, the standard deviation of the distances between the centers of gravity of the adsorbent particles is the standard deviation Lσ, and the value Lσ / La obtained by dividing the standard deviation Lσ by the average La is 0.11 or more and 0.30 or less.
[0014] [7] The optical laminate according to any one of [1] to [6], wherein the adsorptive particles have an average particle diameter of 60.0 nm or more and 140.0 nm or less.
[0015] [8] The optical laminate according to any one of [1] to [7], wherein the first layer further contains solid particles.
[0016] [9] The optical laminate according to any one of [1] to [8], wherein the resin derived from a biomass material contained in the resin substrate is a polyester derived from a biomass material.
[0017]
[10] The optical laminate according to any one of [1] to [9], wherein the first layer further contains a binder resin.
[0018]
[11] The optical laminate according to any one of [1] to
[10] , wherein the content of the adsorbent particles is 15 parts by mass or more and 180 parts by mass or less with respect to 100 parts by mass of the binder resin.
[0019]
[12] The optical laminate according to any one of [1] to
[11] , further comprising a second layer between the resin substrate and the first layer, and the second layer contains a resin derived from a biomass material.
[0020]
[13] The optical laminate according to
[12] , wherein the resin derived from a biomass material is a (meth)acrylic resin derived from a biomass material.
[0021]
[14] The optical laminate according to
[12] or
[13] , wherein the second layer is a hard coat layer.
[0022]
[15] A polarizing plate comprising: a polarizer having a polarizer first surface and a polarizer second surface; a first transparent protective plate arranged on the polarizer first surface side of the polarizer; and a second transparent protective plate arranged on the polarizer second surface side of the polarizer, wherein at least one of the first transparent protective plate and the second transparent protective plate is the optical laminate described in any one of [1] to
[14] , and the optical laminate is arranged so that the surface on the first layer side faces away from the polarizer.
[0023]
[16] A face panel for an image display device, comprising: a plate-like member that is a resin plate or a glass plate; and an optical laminate according to any one of [1] to
[14] , which is placed on the plate-like member; wherein the optical laminate is placed so that the surface on the first layer side faces away from the plate-like member.
[0024]
[17] An image display device comprising: a display element; and the optical laminate according to any one of [1] to
[14] , which is disposed on the display element.
[0025] According to the embodiment of the present disclosure, it is possible to suppress the generation of odor while using a resin derived from a biomass material for the optical laminate.
[0026] Fig. 1 is a cross-sectional view showing an optical laminate according to one embodiment. Fig. 2 is a diagram showing an example of two adjacent adsorptive particles. Fig. 3 is a cross-sectional view showing an image display panel according to one embodiment. Fig. 4 is a diagram schematically showing a state of a continuous folding test.
[0027] Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. In the drawings accompanying this specification, the scale and aspect ratios of the actual objects have been appropriately changed and exaggerated for the sake of ease of illustration and understanding.
[0028] Terms used in this specification that specify shapes and geometric conditions, as well as their degrees, such as terms like "parallel," "perpendicular," and "same," and values of lengths and angles, are not to be construed as being bound by strict meanings, but rather as including a range within which similar functions can be expected.
[0029] In this specification, terms such as "film," "sheet," and "plate" are not to be distinguished from one another solely on the basis of differences in name.
[0030] In this specification, when multiple upper limit value candidates and multiple lower limit value candidates are listed for a certain parameter, the numerical range of the parameter may be constructed by combining any one upper limit value candidate with any one lower limit value candidate. As an example, consider the following statement: "Parameter B may be A1 or more, A2 or more, or A3 or more. Parameter B may be A4 or less, A5 or less, or A6 or less." In this example, the numerical range of parameter B may be A1 or more and A4 or less, A1 or more and A5 or less, A1 or more and A6 or less, A2 or more and A4 or less, A2 or more and A5 or less, A2 or more and A6 or less, A3 or more and A4 or less, A3 or more and A5 or less, or A3 or more and A6 or less.
[0031] In this specification, "suppress" means to restrain or prevent something from happening or occurring. "Suppress" does not only mean to completely prevent something from happening or occurring, but also means to reduce the possibility of something happening or occurring or to make something less likely to happen or occur.
[0032] 1 to 3 are diagrams showing an embodiment of the present invention, in which Fig. 1 is a cross-sectional view showing an optical laminate 1 of the present embodiment.
[0033] The optical laminate 1 includes a resin substrate 10 and a first layer 20. In the example shown in FIG. 1 , the optical laminate 1 further includes a second layer 30. The second layer 30 is a hard coat layer 31. The resin substrate 10 contains a resin derived from a biomass material as a main component. The first layer 20 contains adsorbent particles 21. The adsorbent particles 21 are at least one type of particle selected from hollow particles and porous particles. The optical laminate 1 has a total light transmittance of 70% or more and a haze of 2.0% or less.
[0034] According to such an optical laminate 1, odors caused by the resin derived from biomass materials contained in the resin substrate 10 can be suppressed by the first layer 20 containing the adsorbent particles 21. This makes it possible to suppress the generation of odors while using a resin derived from biomass materials in the optical laminate 1.
[0035] The optical laminate 1 shown in Fig. 1 has a first surface 1a and a second surface 1b located on the opposite side to the first surface 1a. The first surface 1a of the optical laminate 1 is constituted by a first layer 20. The second surface 1b of the optical laminate 1 is constituted by a resin substrate 10. The optical laminate 1 in the example shown in Fig. 1 functions as an antireflection member. In the optical laminate 1 shown in Fig. 1, the first layer 20 functions as a low refractive index layer. The first layer 20 functions as a low refractive index layer, and thereby the optical laminate 1 functions as an antireflection member.
[0036] <Resin Substrate> The resin substrate 10 supports layers other than the resin substrate 10 included in the optical laminate 1. The resin substrate 10 may have at least one of optical transparency, smoothness, and heat resistance. The resin substrate 10 may have high mechanical strength.
[0037] Examples of the resin substrate 10 include plastic films such as polyester, triacetyl cellulose (TAC), cellulose diacetate, cellulose acetate butyrate, polyamide, polyimide, polyethersulfone, polysulfone, polypropylene, polymethylpentene, polyvinyl chloride, polyvinyl acetal, polyether ketone, polymethyl methacrylate, polycarbonate, polyurethane, and amorphous olefin (Cycloolefin Polymer: COP). The resin substrate 10 may be formed by laminating two or more plastic films together.
[0038] From the viewpoint of increasing mechanical strength and ensuring dimensional stability, the resin substrate 10 is preferably a polyester film such as polyethylene terephthalate or polyethylene naphthalate. Among polyester films, the resin substrate 10 is preferably a stretched film, and more preferably a biaxially stretched film. From the viewpoint of increasing light transmittance and ensuring optical isotropy, the resin substrate 10 is preferably TAC or acrylic. From the viewpoint of ensuring weather resistance, the resin substrate 10 is preferably COP or polyester.
[0039] The resin substrate 10 contains a resin derived from a biomass material as a main component. A resin derived from a biomass material is a resin derived from plants. By containing a resin derived from a biomass material as a main component in the resin substrate 10, the environmental impact can be reduced. With respect to the resin substrate 10, "containing a resin derived from a biomass material as a main component" means that the resin substrate 10 accounts for 10% by mass or more of the resin substrate 10. When the resin substrate 10 contains a resin derived from a biomass material as a main component, the resin derived from the biomass material may account for 50% by mass or more, or may account for 90% by mass or more of the resin substrate 10.
[0040] Whether or not a resin is derived from a biomass material can be determined by measuring radioactive carbon (C14). Carbon dioxide in the atmosphere contains a certain proportion (105.5 pMC) of C14. For this reason, it is known that the C14 content in plants that grow by absorbing carbon dioxide from the atmosphere is also about 105.5 pMC. Furthermore, it is known that fossil fuels contain very little C14. Therefore, by measuring the proportion of C14 in the total carbon atoms in the resin, it is possible to determine whether or not the resin is derived from a biomass material.
[0041] The biomass-derived resin contained in the resin substrate 10 is preferably a biomass-derived polyester, which increases mechanical strength, ensures dimensional stability, and reduces environmental impact. The biomass-derived resin contained in the resin substrate 10 may be a biomass-derived polyethylene terephthalate (PET).
[0042] The thickness of the resin substrate 10 is preferably 5 μm or more, more preferably 20 μm or more, and even more preferably 30 μm or more. The thickness of the resin substrate 10 is preferably 300 μm or less, more preferably 200 μm or less, and even more preferably 120 μm or less.
[0043] The thickness of the resin substrate 10 can be measured using a general-purpose film thickness measuring device. An example of a film thickness measuring device is a Digimatic Standard Outside Micrometer (Mitutoyo Corporation, product number "MDC-25SX"). The thickness of the resin substrate 10 is determined by measuring the thickness at any 10 points on the resin substrate 10 and averaging the thicknesses.
[0044] To improve adhesiveness, the surface of the resin substrate 10 may be subjected to physical treatment such as corona discharge treatment or chemical treatment, or an easy-adhesion layer may be formed.
[0045] The total light transmittance of the resin substrate 10 as defined in JIS K7361-1:1997 is preferably 70% or more, more preferably 80% or more, and even more preferably 85% or more.
[0046] <First Layer> The first layer 20 is a layer that suppresses odors caused by the resin derived from the biomass material contained in the resin substrate 10. The first layer 20 is located closer to the first surface 1a than the resin substrate 10. In the example shown in Fig. 1 , the first layer 20 constitutes the first surface 1a of the optical laminate 1. In the optical laminate 1 shown in Fig. 1 , the first layer 20 functions as a low refractive index layer.
[0047] The first layer 20 contains adsorbent particles 21. In the example shown in Fig. 1, the first layer 20 further contains a binder resin 22. In the example shown in Fig. 1, the binder resin 22 is located between the adsorbent particles 21. In the example shown in Fig. 1, the first layer 20 further contains solid particles 23. Although not shown, the first layer 20 may further contain a leveling agent.
[0048] <Adsorbent Particles> The adsorbent particles 21 adsorb odor components released from the biomass-derived resin contained in the resin substrate 10. In particular, impurities may be mixed into the resin during the process of producing the biomass-derived resin. In particular, when the biomass-derived resin contained in the resin substrate 10 is polyethylene terephthalate (PET) derived from the biomass material, nitrogen elements derived from the biomass material may be mixed into the resin during the process of producing the raw material for PET. Furthermore, to reduce the effects of these impurities, it may be necessary to add additives to the resin depending on the impurities expected to be mixed in. In these cases, odor components may be released from impurities or additive residues contained in the biomass-derived resin. The adsorbent particles 21 adsorb odor components released from these residues. By adsorbing odor components, the adsorbent particles 21 suppress the generation of odors caused by the biomass-derived resin, particularly the residues contained in the resin.
[0049] The adsorbent particles 21 are at least one type of particle selected from hollow particles and porous particles. Hollow particles refer to particles that have an outer shell layer, and the interior of the particle surrounded by the outer shell layer is hollow, with air contained within the hollow. When the adsorbent particles 21 are hollow particles, odor components are adsorbed to the hollow particles by being trapped in the hollow particles. Porous particles refer to particles with pores that are open on the surface of the particle. The pores formed in the porous particles may or may not penetrate the porous particles. When the adsorbent particles 21 are porous particles, odor components are adsorbed to the porous particles by being trapped in the pores of the porous particles.
[0050] The adsorbent particles 21 may be light-transmitting particles. When the adsorbent particles 21 are light-transmitting particles, the refractive index of the first layer 20 can be lowered by the adsorbent particles 21. This allows the first layer 20 to function as a low-refractive-index layer. When the adsorbent particles 21 are hollow and light-transmitting particles, the refractive index decreases as the porosity of the hollow particles increases. When the adsorbent particles 21 are porous and light-transmitting particles, the refractive index decreases as the volume of the portions of the pores formed in the porous particles that are not filled with the binder resin 22 increases.
[0051] The material of the adsorbent particles 21 may be either an inorganic compound such as silica or magnesium fluoride, or an organic compound. As an example, the adsorbent particles 21 are metal oxide particles. In this case, the adsorbent particles 21 may contain silica or alumina. From the viewpoint of further lowering the refractive index of the first layer 20 when the first layer 20 is made to function as a low refractive index layer, and from the viewpoint of increasing the strength of the adsorbent particles 21, it is preferable that the adsorbent particles 21 contain silica. It is preferable that the adsorbent particles 21 include hollow silica particles. Hollow silica particles are hollow particles whose outer shell layer is made of silica.
[0052] FIG. 2 is a diagram showing an example of two adjacent adsorbent particles 21 in a first layer 20. Point G indicates the position of the center of gravity of the adsorbent particle 21. The average of the distances w1 between the centers of gravity of the adsorbent particles 21 in the first layer 20 is defined as the average La. Furthermore, the standard deviation of the distances w1 between the centers of gravity of the adsorbent particles 21 in the first layer 20 is defined as the standard deviation Lσ. In this case, the average La is preferably 90 nm or more and 130 nm or less. The average La is more preferably 110 nm or more and 120 nm or less. Furthermore, the value Lσ / La obtained by dividing the standard deviation Lσ by the average La is preferably 0.11 or more and 0.30 or less. The value Lσ / La obtained by dividing the standard deviation Lσ by the average La is more preferably 0.16 or more and 0.23 or less.
[0053] <Method of Measuring Average La and Standard Deviation Lσ> Average La and standard deviation Lσ are measured by the following procedures (1) to (5).
[0054] (1) The first surface 1a of the optical laminate 1 is imaged using a scanning electron microscope. The magnification during imaging is 30,000 times. The imaging area, excluding the scale bar, is adjusted to have a size of 4.0 μm horizontally and 3.0 μm vertically. Furthermore, the pixel size is adjusted to 3.31 nm.
[0055] The image captured in (1) above is a planar image of the first layer 20. The presence of the adsorptive particles 21 can be confirmed from the planar image of the first layer 20. In (1) above, the acceleration voltage of the scanning electron microscope (SEM) is preferably 100 V or more and 30 kV or less. The scanning electron microscope (SEM) used for the measurement is, for example, the "SU9000" model manufactured by Hitachi High-Tech Corporation.
[0056] (2) Remove unnecessary parts that do not contain image information derived from the sample, such as the scale bar, from the 30,000x image obtained in (1) above. The image from which unnecessary parts have been removed is then binarized using the image analysis freeware "ImageJ" developed by the National Institutes of Health (NIH) and the plug-in package "Fiji" for the above software, using the following procedure to binarize the image so that bright areas are white and dark areas are black. <Procedure> 1. Image Selection: Select the image in ImageJ. You can select the image by selecting Open from the File tab. 2. Image Sizing: Adjust the image size. From the Image tab, select Size under Adjust, set the settings to "Width 1208, Height 906," check Constrain aspect ratio, check Average when downsizing, and select Bilinear for Interpolation to adjust the image size. 3. Image Cropping: Crop the image. You can crop the image by selecting Crop from the Image tab. 4. Filtering: Perform filtering. Filtering can be performed by selecting Kuwahara Filter under Filters in the Process tab and entering 5 for Sampling window width. 5. Binarization: Binarization can be performed by selecting AutoLocal Threshold under Adjust in the Image tab, selecting Median, Radius as Method and entering 30, entering 0 for Parameter 1, entering 0 for Parameter 2, and checking White objects on black background. 6. Noise removal: Noise can be removed by selecting Despeckle under Noise in the Process tab. 7. Particle separation: Particles can be separated. Particles can be separated by selecting WaterShed under Binary in the Process tab. 8. Noise removal: Noise can be removed by selecting Open under Binary in the Process tab. 9. Particle coordinate analysis: Particle coordinate analysis can be performed.You can perform particle coordinate analysis by selecting Analyze Particles from the Analyze tab, entering 0-Infinity for Size, 0.00-1.00 for Circularity, entering Nothing for Show, checking Display results, and checking Clear results.
[0057] (3) By binarizing, an image is obtained in which a large number of white areas are arranged within a black area. The white areas can be considered to be areas corresponding to the adsorptive particles 21.
[0058] (4) For white areas of 100 square pixels or more in the binarized image, calculate the coordinates of the center of gravity using the Analyze Particles function in Fiji. Next, calculate the average and standard deviation of the distance between the centers of gravity of adjacent particles.
[0059] In (4) above, "adjacent particles" refers to a combination of particles whose center-of-gravity distance is 50 nm or more and 150 nm or less. Furthermore, "average value of the distance between the centers of gravity of adjacent particles" refers to the average value of the distance between the centers of gravity of all adjacent particles. The reason for limiting the definition of adjacent particles to "a combination of particles whose center-of-gravity distance is 50 nm or more and 150 nm or less" is that when the distance between the centers of gravity is less than 50 nm, noise that was not completely removed by the binarization in (2) above may have an effect, and when the distance between the centers of gravity is more than 150 nm, there is a possibility that adjacent particles may be counted.
[0060] (5) By performing the above steps (1) to (4), the "average distance between the centers of gravity of the adsorbent particles 21 in the first layer 20" and the "standard deviation of the distance between the centers of gravity of the adsorbent particles 21 in the first layer 20" can be calculated in any one measurement region of the optical laminate 1. Furthermore, the above steps (1) to (4) are performed in other nine locations of the optical laminate 1, and the "average distance between the centers of gravity of the adsorbent particles 21 in the first layer 20" and the "standard deviation of the distance between the centers of gravity of the adsorbent particles 21 in the first layer 20" are calculated for a total of 10 locations. The average of the "average distance between the centers of gravity of the adsorbent particles 21 in the first layer 20" at the 10 locations is defined as the "average La" in the present disclosure. Similarly, the average of the "standard deviation of the distance between the centers of gravity of the adsorbent particles 21 in the first layer 20" at the 10 locations is defined as the "standard deviation Lσ" in the present disclosure. The 10 measurement points can be selected at random from points that are visually free of any abnormalities such as dust or scratches.
[0061] <Technical Significance of Average La and Standard Deviation Lσ> The average La, which is the average of the distances w1 between the centers of gravity of the adsorbent particles 21 in the first layer 20, indicates the degree of density in the planar direction of the adsorbent particles 21 having an average particle diameter of 60.0 nm or more and 140.0 nm or less. Specifically, it can be said that when the average La is small, the degree of density of the adsorbent particles 21 is high, and when the average La is large, the degree of density of the adsorbent particles 21 is low.
[0062] The standard deviation Lσ, which is the standard deviation of the distance w1 between the centers of gravity of the adsorbent particles 21 in the first layer 20, represents the degree of variation in the distribution of the adsorbent particles 21 in the planar direction, with an average particle diameter of 60.0 nm or more and 140.0 nm or less. Similarly, Lσ / La represents the degree of variation in the distribution of the adsorbent particles 21 in the planar direction, with an average particle diameter of 60.0 nm or more and 140.0 nm or less. Since Lσ / La represents the degree of variation in the distribution of the adsorbent particles 21 as a quantity independent of the average particle diameter of the adsorbent particles 21, it is considered to be more appropriate for indicating the degree of variation in the distribution of the adsorbent particles 21 than the standard deviation Lσ. It can be said that the smaller Lσ / La is, the more uniform the distribution of the adsorbent particles 21, and the larger Lσ / La is, the more non-uniform the distribution of the adsorbent particles 21.
[0063] In this specification, unless otherwise specified, measurements of La and Lσ, as well as other measurements such as element ratios and haze, are performed in an atmosphere at a temperature of 23±5°C and a relative humidity of 40% to 65%. Before starting each measurement, the target sample is exposed to the atmosphere for 30 minutes to 60 minutes before the measurement.
[0064] <Average particle diameter> As an example, the adsorbent particles 21 have an average particle diameter of 60.0 nm or more and 140.0 nm or less. The lower limit of the average particle diameter of the adsorbent particles 21 is preferably 60.0 nm or more, preferably 65.0 nm or more, more preferably 80.0 nm or more, more preferably 81.0 nm or more, and even more preferably 82.0 nm or more. The upper limit of the average particle diameter of the adsorbent particles 21 is preferably 120.0 nm or less, more preferably 110.0 nm or less. The upper limit of the average particle diameter of the adsorbent particles 21 may be 100.0 nm or less.
[0065] <Method for Measuring Average Particle Diameter> A method for measuring the average particle diameter of the adsorbent particles 21, as well as the solid particles 23 and high refractive index particles described below, will be described. The average particle diameter of the adsorbent particles 21 is calculated by the following steps A1 to A3. A1: The cross section of the optical laminate 1 is imaged using an STEM. The acceleration voltage of the STEM is preferably 10 kV or more and 30 kV or less, and the magnification is preferably 50,000 times or more and 100,000 times or less. A2: All adsorbent particles 21 in the first layer 20 are extracted from the observed image. The minimum number of adsorbent particles 21 to be extracted is 20. If the number of adsorbent particles 21 extracted in one observed image does not reach 20, another location on the cross section of the optical laminate 1 is imaged using the STEM, and two or more observed images are used. Then, the particle diameter of each adsorbent particle 21 is calculated. The particle diameter of an individual adsorbent particle 21 means the distance between two lines that is the longest when the cross section of the adsorbent particle 21 is sandwiched between any two parallel lines. The outer shell of the adsorbent particle 21 appears as a thick line. The particle diameter is measured from the outside of the line. A3: From all the adsorbent particles 21 whose particle diameters were measured in A2, the bottom 10% of adsorbent particles 21 in particle diameter are excluded. The "%" is based on the number and is rounded off. The average value of the particle diameters of the remaining 90% of adsorbent particles 21 is taken as the average particle diameter of the adsorbent particles 21.
[0066] In the above A3, the reasons for excluding the adsorbent particles 21 with particle diameters in the bottom 10% are (1) and (2) below: (1) The adsorbent particles 21 with small measured particle diameters may have been cut at a location away from the center of the adsorbent particles 21. (2) The adsorbent particles 21 with small measured particle diameters may have been partially buried in a layer adjacent to the first layer 20, such as a high refractive index layer or a hard coat layer.
[0067] In the above steps A1 to A3, if the particles to be extracted are changed to all solid particles 23 in the first layer 20, it is possible to calculate the average particle diameter of the solid particles 23, which will be described later. Also, in the above steps A1 to A3, if the particles to be extracted are changed to all high-refractive-index particles in the high-refractive-index layer, which will be described later, it is possible to calculate the average particle diameter of the high-refractive-index particles.
[0068] A sample with an exposed cross section of the optical laminate 1 can be prepared, for example, by the following steps X1 to X2. X1: The optical laminate 1 is cut to a desired size to prepare a cut sample, and then the cut sample is embedded in resin to prepare an embedded sample. The cut sample is, for example, a strip measuring 10 mm long and 3 mm wide. The embedding resin is epoxy resin. The embedded sample can be obtained, for example, by the following method. First, the cut sample is placed in a silicon embedding plate, and then the embedding resin is poured in. Next, the embedding resin is cured. Then, the cut sample and the embedding resin surrounding it are removed from the silicon embedding plate. This results in an embedded sample. In the case of the epoxy resin manufactured by Struers exemplified below, the aforementioned curing process is preferably performed by leaving it at room temperature for 12 hours to harden. The embedded sample is shaped like a block. The silicon embedding plate is, for example, manufactured by Dosaka EM Co., Ltd. The silicon embedding plate is also sometimes called a silicon capsule. The epoxy resin for embedding may be, for example, a mixture of "Epofix" (trade name) manufactured by Struers and "Epofix Hardener" (trade name) manufactured by the same company in a ratio of 10:1.2.
[0069] X2: The block-shaped embedded sample is cut vertically to produce a sliced sample exposing the cross section of the optical laminate 1. The embedded sample is cut with a microtome using a glass knife and a diamond knife. The microtome is, for example, an "Ultramicrotome EM UC7" manufactured by Leica Microsystems. When cutting the block-shaped embedded sample with this device, the sample is first roughly cut with a glass knife to produce a surface approximately 100 μm long x 20 μm wide, including the cross section of the coated surface (coarse trimming). Finally, this surface is cut with a diamond knife under the conditions of "SPEED: 1.40 mm / s" and "FEED: 80 nm," and the floating slice is collected with a mesh. A collodion-coated mesh (Cat. No. 651) manufactured by Nissin EM can be used as the mesh.
[0070] The lower limit of the porosity of the adsorbent particle 21 is, for example, preferably 5% or more, more preferably 10% or more, and even more preferably 20% or more, from the viewpoint of reducing the refractive index. The upper limit of the porosity of the adsorbent particle 21 is, for example, preferably 80% or less, more preferably 70% or less, and even more preferably 60% or less, from the viewpoint of strength. The porosity of the adsorbent particle 21 is calculated according to B1 to B3 below. B1: The cross section of the adsorbent particle 21 is measured using STEM observation or the like to measure the diameter and the thickness of the outer shell excluding the void portion. B2: Assuming that the adsorbent particle 21 is a sphere, the volume of the void portion of the adsorbent particle 21 and the volume of the adsorbent particle 21 without the void portion are calculated. B3: The porosity is calculated according to {(volume of the void portion of the adsorbent particle 21) / (volume of the adsorbent particle 21 without the void portion)} × 100.
[0071] The content of the adsorbent particles 21 is, for example, 15 parts by mass or more and 180 parts by mass or less per 100 parts by mass of the binder resin 22. The lower limit of the content of the adsorbent particles 21 is more preferably 17 parts by mass or more, and more preferably 20 parts by mass or more per 100 parts by mass of the binder resin 22. The upper limit of the content of the adsorbent particles 21 is more preferably 95 parts by mass or less, more preferably 90 parts by mass or less, and more preferably 85 parts by mass or less per 100 parts by mass of the binder resin 22.
[0072] When the refractive index of the first layer 20 is lowered by the adsorbent particles 21 so that the first layer 20 functions as a low refractive index layer, the greater the content of the adsorbent particles 21, the more the refractive index of the first layer 20 can be lowered.
[0073] The surfaces of the adsorbent particles 21 are preferably coated with a silane coupling agent. The silane coupling agent preferably has a (meth)acryloyl group or an epoxy group, and more preferably has a methacryloyl group. By subjecting the adsorbent particles 21 to surface treatment with a silane coupling agent, the affinity between the adsorbent particles 21 and the binder resin 22 is improved, making it easier to suppress excessive aggregation of the adsorbent particles 21. Therefore, by subjecting the adsorbent particles 21 to surface treatment with a silane coupling agent, it is easier to set Lσ and Lσ / La within the above ranges.
[0074] The solid particles 23 described below are also preferably surface-coated with a silane coupling agent to prevent excessive aggregation.
[0075] The adsorbent particles 21 may include two or more types of adsorbent particles 21. For example, the adsorbent particles 21 may include adsorbent particles 21 made of different materials. The adsorbent particles 21 may include adsorbent particles 21 with different particle diameters. The adsorbent particles 21 may include both the hollow particles and porous particles described above.
[0076] When two or more types of adsorptive particles 21 with different particle diameters are included as the adsorptive particles 21, the small adsorptive particles 21 tend to be embedded between the large adsorptive particles 21, making it easier to control the thickness of the low refractive index layer. Therefore, by including two or more types of adsorptive particles 21 with different particle diameters, it becomes easier to adjust the reflectance and reflected hue. In part of the low refractive index layer, small adsorptive particles 21 may overlap large adsorptive particles 21.
[0077] When two or more types of adsorbent particles 21 with different particle diameters are used, it is preferable to include large particles with a particle diameter of 90.0 nm or more and small particles with a particle diameter of less than 90.0 nm. The upper limit of the particle diameter of the large particles is preferably 140.0 nm or less, more preferably 110.0 nm or less, and even more preferably 105.0 nm or less. The lower limit of the particle diameter of the large particles is more preferably 93.0 nm or more, more preferably 95.0 nm or more, and even more preferably 100.0 nm or more. The upper limit of the particle diameter of the small particles is more preferably 82.0 nm or less, more preferably 80.0 nm or less, and even more preferably 75.0 nm or less. The lower limit of the particle diameter of the small particles is preferably 60.0 nm or more, more preferably 65.0 nm or more, more preferably 70.0 nm or more, and even more preferably 72.0 nm or more.
[0078] As an example, the proportion of the mass of the adsorbent particles 21 having a particle diameter of 90.0 nm or more to the total mass of the adsorbent particles 21 contained in the first layer 20 is 30% or more. The proportion of the mass of the adsorbent particles 21 having a particle diameter of 100.0 nm or more to the total mass of the adsorbent particles 21 contained in the first layer 20 may be 30% or more. The proportion of the mass of the adsorbent particles 21 having a particle diameter of 90.0 nm or more to the total mass of the adsorbent particles 21 contained in the first layer 20 may be 80% or less. The proportion of the mass of the adsorbent particles 21 having a particle diameter of 100.0 nm or more to the total mass of the adsorbent particles 21 contained in the first layer 20 may be 80% or less.
[0079] <Binder Resin> In one example, the binder resin 22 contained in the first layer 20 includes a cured product of a curable resin composition. The curable resin composition is a composition containing a curable compound such as a thermosetting resin or an ionizing radiation-curable compound. The proportion of the cured product of the curable resin composition to the total binder resin 22 in the first layer 20 is preferably 50% by mass or more, more preferably 70% by mass or more, more preferably 90% by mass or more, and most preferably 100% by mass. Examples of the curable resin composition of the first layer 20 include a thermosetting resin composition or an ionizing radiation-curable resin composition, and an ionizing radiation-curable resin composition is preferred. That is, the first layer 20 preferably includes, as the binder resin 22, a cured product of an ionizing radiation-curable resin composition.
[0080] A thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that cures when heated. Examples of thermosetting resins include acrylic resins, urethane resins, phenolic resins, urea-melamine resins, epoxy resins, unsaturated polyester resins, and silicone resins. In a thermosetting resin composition, a curing agent is added to the curable resin as needed.
[0081] The ionizing radiation-curable resin composition is a composition containing a compound having an ionizing radiation-curable functional group (hereinafter also referred to as "ionizing radiation-curable compound"). Examples of the ionizing radiation-curable functional group include ethylenically unsaturated bond groups such as (meth)acryloyl groups, vinyl groups, and allyl groups, as well as epoxy groups and oxetanyl groups. The ionizing radiation-curable compound preferably has two or more ionizing radiation-curable functional groups. The ionizing radiation-curable compound is preferably a compound having an ethylenically unsaturated bond group. The ionizing radiation-curable compound is more preferably a (meth)acrylate-based compound having a (meth)acryloyl group. Either a monomer or an oligomer can be used as the (meth)acrylate-based compound. The (meth)acrylate-based compound is preferably a polyfunctional (meth)acrylate-based compound. In this specification, the polyfunctional (meth)acrylate-based compound refers to a compound having two or more (meth)acryloyl groups. In this specification, the "polysilsesquioxane substituted with one or more reactive groups" described below is to be distinguished from the "(meth)acrylate compound." In other words, in this specification, the "(meth)acrylate compound" is a concept that does not include the "polysilsesquioxane substituted with one or more reactive groups."
[0082] The ionizing radiation-curable compound preferably includes a polyfunctional (meth)acrylate compound. In other words, the first layer 20 preferably includes, as the binder resin 22, a cured product of a polyfunctional (meth)acrylate compound. The polyfunctional (meth)acrylate compound may be a polyfunctional (meth)acrylate compound containing fluorine atoms. In other words, the first layer 20 may include, as the binder resin 22, a cured product of a polyfunctional (meth)acrylate compound containing fluorine atoms. When the binder resin 22 includes a cured product of a polyfunctional (meth)acrylate compound containing fluorine atoms, the proportion of fluorine atoms in the polyfunctional (meth)acrylate compound containing fluorine atoms is preferably 5% by mass or more and 80% by mass or less. More preferably, the proportion of fluorine atoms in the polyfunctional (meth)acrylate compound containing fluorine atoms is 10% by mass or more and 70% by mass or less.
[0083] The polyfunctional (meth)acrylate compound preferably contains an oligomer. Monomers are more likely to uniformly align the adsorptive particles 21 than oligomers. For this reason, if only a monomer is used as the polyfunctional (meth)acrylate compound, Lσ / La may become excessively small. On the other hand, by including an oligomer as the polyfunctional (meth)acrylate compound, it is easier to keep Lσ / La within the above range.
[0084] The fluorine atom-containing polyfunctional (meth)acrylate compound may be either a monomer or an oligomer, but is preferably an oligomer. The oligomer as the fluorine atom-containing polyfunctional (meth)acrylate compound preferably has a weight-average molecular weight of 5,000 to 100,000, more preferably 5,000 to 50,000. If the weight-average molecular weight of the fluorine-containing compound is 5,000 or more, the first layer 20 is less susceptible to contamination. If the weight-average molecular weight of the fluorine-containing compound is 100,000 or less, good solubility in organic solvents is obtained. Therefore, a first layer 20 having a uniform and homogeneous surface is easily obtained. In this specification, the weight-average molecular weight means the average molecular weight measured by GPC analysis and converted into standard polystyrene. The fluorine atom-containing polyfunctional (meth)acrylate compound oligomer preferably has 2 to 8 (meth)acryloyl groups, more preferably 3 to 7 (meth)acryloyl groups.
[0085] The proportion of the cured product of the polyfunctional (meth)acrylate compound containing fluorine atoms relative to the total amount of the binder resin 22 is preferably 50% by mass or more, more preferably 55% by mass or more, and even more preferably 65% by mass or more.
[0086] The fluorine atom-containing polyfunctional (meth)acrylate compound preferably has a perfluoropolyether group. That is, the fluorine atom-containing polyfunctional (meth)acrylate compound is preferably a polyfunctional (meth)acrylate compound having a perfluoropolyether group. Examples of polyfunctional (meth)acrylate compounds having a perfluoropolyether group include the compounds described in JP 2010-285501 A.
[0087] The ionizing radiation curable compounds may be used alone or in combination of two or more.
[0088] When the ionizing radiation-curable compound is an ultraviolet-curable compound, the coating liquid for the first layer 20 preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator. Examples of the photopolymerization initiator include one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyl dimethyl ketal, benzoyl benzoate, α-acyloxime ester, α-aminoalkylphenone, thioxanthones, etc. The photopolymerization accelerator can reduce polymerization inhibition by air during curing and increase the curing rate, and examples of the photopolymerization accelerator include one or more selected from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester, etc.
[0089] Further preferred curable compounds include polysilsesquioxane. That is, the first layer 20 preferably contains a cured product of polysilsesquioxane as the binder resin 22. By including a cured product of polysilsesquioxane as the binder resin 22, the hardness of the first layer 20 can be increased, making it easier to improve the scratch resistance of the first layer 20. The cured product of polysilsesquioxane is likely to improve the toughness of not only the surface of the layer but the entire layer, and is therefore thought to be easy to improve the scratch resistance of the first layer 20. Furthermore, the cured product of polysilsesquioxane has good adhesion to silica, and is therefore thought to be easy to improve the scratch resistance of the first layer 20.
[0090] When the first layer 20 functions as a low-refractive index layer, the following effects are obtained by including fluorine atoms in the binder resin 22. The refractive index of the first layer 20 can be lowered because the fluorine atom content in the first layer 20 is increased. This allows the first layer 20 to function as a low-refractive index layer with a lower refractive index. Conversely, if the refractive index of the first layer 20 can be sufficiently lowered without including fluorine atoms in the binder resin 22, it is preferable that the binder resin 22 does not include fluorine atoms. The absence of fluorine atoms in the binder resin 22 can prevent the release of organic fluorine compounds (PFAS) due to the binder resin 22 during the production and disposal of the optical laminate 1. Furthermore, the absence of fluorine atoms in the binder resin 22 allows the first layer 20 to more effectively adsorb odor components.
[0091] 1 , the first layer 20 contains solid particles 23 in addition to the adsorbent particles 21. By including the solid particles 23 in addition to the adsorbent particles 21 in the first layer 20, the scratch resistance of the first layer 20 can be improved. Furthermore, by including the solid particles 23 in addition to the adsorbent particles 21 in the first layer 20, the adsorbent particles 21 are less likely to settle in a wet state, making it easier to control the arrangement of the adsorbent particles 21. Therefore, the arrangement of the adsorbent particles 21 can be favorable for suppressing odor generation or lowering the refractive index of the first layer 20. For example, La and Lσ / La can be within the above-mentioned ranges.
[0092] The material of the solid particles 23 is preferably an inorganic compound such as silica or magnesium fluoride, and more preferably silica. In other words, the solid particles 23 are more preferably solid silica particles.
[0093] The average particle diameter of the solid particles 23 is preferably smaller than the average particle diameter of the adsorbent particles 21. The lower limit of the average particle diameter of the solid particles 23 is preferably 5 nm or more, and more preferably 10 nm or more. The upper limit of the average particle diameter of the solid particles 23 is preferably 80 nm or less, more preferably 20 nm or less, and even more preferably 15 nm or less. If the upper limit of the average particle diameter of the solid particles 23 is 15 nm or less, the arrangement of the adsorbent particles 21 can be more stably controlled to a preferred arrangement.
[0094] From the viewpoint of improving scratch resistance, the content of the solid particles 23 is preferably 10 parts by mass or more, and more preferably 20 parts by mass or more, per 100 parts by mass of the binder resin 22. On the other hand, if the content of the solid particles 23 is too high, the solid particles 23 may be more likely to aggregate. For this reason, the content of the solid particles 23 is preferably 75 parts by mass or less, and more preferably 50 parts by mass or less, per 100 parts by mass of the binder resin 22. The content of the solid particles 23 is preferably 10 parts by mass or more, and more preferably 20 parts by mass or more, per 100 parts by mass of the binder resin 22.
[0095] <Leveling Agent> The first layer 20 preferably contains a leveling agent. From the viewpoint of making it easier for the leveling agent to function, the leveling agent preferably has a reactive group. Examples of the reactive group include a (meth)acryloyl group, a vinyl group, and an epoxy group. In particular, the reactive group is preferably a (meth)acryloyl group.
[0096] Examples of the leveling agent include silicone-based leveling agents and fluorine-based leveling agents. The silicone-based leveling agent may contain a small amount of fluorine atoms. The fluorine-based leveling agent may contain a small amount of silicon atoms. In order to reduce the environmental burden, a silicone-based leveling agent that does not contain fluorine atoms is preferred. By using a silicone-based leveling agent that does not contain fluorine atoms, it is possible to suppress the emission of organic fluorine compounds (PFAS) during the production and disposal of the optical laminate 1. Therefore, it is possible to reduce the environmental burden during the production and disposal of the optical laminate 1. Since fluorine-based leveling agents have a relatively low hardness, when greater scratch resistance is required, a silicone-based leveling agent may be used as the leveling agent.
[0097] The lower limit of the content of the leveling agent is preferably 2 parts by mass or more, more preferably 3 parts by mass or more, and even more preferably 4 parts by mass or more, relative to 100 parts by mass of the binder resin 22. The upper limit of the content of the leveling agent is preferably 15 parts by mass or less, more preferably 10 parts by mass or less, and even more preferably 6 parts by mass or less, relative to 100 parts by mass of the binder resin 22. By setting the content of the leveling agent within the above range, it is possible to suppress a decrease in the scratch resistance of the low refractive index layer.
[0098] The first layer 20 may further contain additives such as antistatic agents, antioxidants, surfactants, dispersants, light stabilizers, and ultraviolet absorbers.
[0099] It is preferable not to use an additive containing a fluorine atom from the viewpoint of suppressing emission of organic fluorine compounds (PFAS) caused by the additive during production and disposal of the optical laminate 1. By not using an additive containing a fluorine atom, the environmental load during production and disposal of the optical laminate 1 can be reduced.
[0100] The lower limit of the thickness T of the first layer 20 is preferably 80 nm or more, more preferably 85 nm or more, and more preferably 90 nm or more. The upper limit of the thickness T of the first layer 20 is preferably 150 nm or less, more preferably 300 nm or less, and more preferably 200 nm or less. By setting the upper limit of the thickness T as described above, the haze of the optical laminate 1, which will be described later, can be sufficiently reduced. In this specification, the thickness of the layers other than the resin substrate 10 constituting the optical laminate 1, including the first layer 20, can be calculated by selecting any 20 locations in a cross-sectional photograph of the optical laminate 1 taken by a scanning transmission electron microscope and averaging the thicknesses at the 20 locations.
[0101] When the thickness of the first layer 20 is T and the average particle diameter of the adsorptive particles 21 is D, T / D is, for example, 0.80 or more and 1.30 or less. By setting T / D to 1.30 or less, the refractive index of the first layer 20 can be reduced when the first layer 20 is made to function as a low refractive index layer.
[0102] When the first layer 20 functions as a low refractive index layer, the lower limit of the refractive index of the first layer 20 is preferably 1.10 or more, more preferably 1.20 or more, more preferably 1.26 or more, more preferably 1.28 or more, and more preferably 1.30 or more. The upper limit of the refractive index of the first layer 20 is preferably 1.48 or less, more preferably 1.45 or less, more preferably 1.40 or less, more preferably 1.38 or less, and more preferably 1.35 or less. In this specification, the refractive indexes of the layers constituting the optical laminate 1, such as the first layer 20 and the high refractive index layer described later, mean values at a wavelength of 589.3 nm.
[0103] The first layer 20 can be formed by applying a coating liquid for the first layer 20 containing the components constituting the first layer 20 and a solvent, drying the coating liquid, and, if necessary, curing the coating liquid by irradiating it with ionizing radiation.
[0104] <Solvent> Examples of solvents include ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone (MIBK), and cyclohexanone; ethers such as dioxane and tetrahydrofuran; aliphatic hydrocarbons such as hexane; alicyclic hydrocarbons such as cyclohexane; aromatic hydrocarbons such as toluene and xylene; halogenated carbons such as dichloromethane and dichloroethane; esters such as methyl acetate, ethyl acetate, and butyl acetate; alcohols such as isopropanol, butanol, and cyclohexanol; cellosolves such as methyl cellosolve and ethyl cellosolve; glycol ethers such as propylene glycol monomethyl ether acetate; cellosolve acetates; sulfoxides such as dimethyl sulfoxide; and amides such as dimethylformamide and dimethylacetamide. The solvent contained in the coating liquid solvent for the first layer 20 may be a mixture of the above-mentioned solvents.
[0105] The solvent of the coating liquid for the first layer 20 preferably contains multiple solvents with different evaporation rates. Specifically, it is preferable to contain three types of solvents: a solvent with a slow evaporation rate, a solvent with a normal evaporation rate, and a solvent with a fast evaporation rate. By containing multiple solvents, the solvents evaporate gradually, making it easier to control the arrangement of the adsorbent particles 21.
[0106] As used herein, a solvent with a slow evaporation rate refers to a solvent with an evaporation rate of less than 70, where the evaporation rate of butyl acetate is taken as 100. As used herein, a solvent with a standard evaporation rate refers to a solvent with an evaporation rate of 70 or more but less than 220, where the evaporation rate of butyl acetate is taken as 100. As used herein, a solvent with a fast evaporation rate refers to a solvent with an evaporation rate of 220 or more, where the evaporation rate of butyl acetate is taken as 100. Examples of solvents with a slow evaporation rate include cyclohexanone (evaporation rate 32), 1-methoxy-2-propyl acetate (evaporation rate 44), and propylene glycol monomethyl ether acetate (evaporation rate 44). Examples of solvents with a standard evaporation rate include butyl acetate (evaporation rate 100), methyl isobutyl ketone (evaporation rate 160), and toluene (evaporation rate 200). Examples of solvents with a fast evaporation rate include methylcyclohexanone (evaporation rate 320) and methyl ethyl ketone (evaporation rate 370).
[0107] The ratio of the solvent with a slow evaporation rate to the total amount of solvent is preferably 10% by mass to 50% by mass, and more preferably 15% by mass to 45% by mass. The ratio of the solvent with a normal evaporation rate to the total amount of solvent is preferably 30% by mass to 70% by mass, and more preferably 35% by mass to 65% by mass. The ratio of the solvent with a fast evaporation rate to the total amount of solvent is preferably 5% by mass to 35% by mass, and more preferably 10% by mass to 30% by mass.
[0108] <Drying Conditions> The drying temperature of the coating liquid for the first layer 20 is preferably 30°C or higher and 80°C or lower, and more preferably 38°C or higher and 70°C or lower. By setting the drying temperature to 38°C or higher, excessive aggregation of the adsorbent particles 21 can be suppressed, and it is easy to prevent Lσ / La from becoming too large. By setting the drying temperature to 70°C or lower, it is easy to cause the adsorbent particles 21 to moderately aggregate, and it is easy to prevent Lσ / La from becoming too small. This allows the adsorbent particles 21 to be arranged in a manner that is preferable for suppressing odor generation or lowering the refractive index of the first layer 20. The wind speed of the drying air for the coating liquid for the first layer 20 is preferably 0.1 m / s or higher and 30 m / s or lower, and more preferably 0.3 m / s or higher and 25 m / s or lower.
[0109] <Second Layer> In the example shown in Fig. 1 , the optical laminate 1 further includes a second layer 30 between the resin substrate 10 and the first layer 20. In the example shown in Fig. 1 , the second layer 30 is a hard coat layer 31. When the optical laminate 1 includes the hard coat layer 31 as the second layer 30, the scratch resistance of the optical laminate 1 can be improved. When the optical laminate 1 further includes a high refractive index layer described later between the resin substrate 10 and the first layer 20, the optical laminate 1 preferably includes the resin substrate 10, the second layer 30, the high refractive index layer, and the first layer 20 in this order.
[0110] As an example, the second layer 30 contains a resin derived from a biomass material. In this case, the resin derived from a biomass material contained in the second layer 30 may be a (meth)acrylic resin derived from a biomass material. When the second layer 30 contains a resin derived from a biomass material, the environmental load can be further reduced. When the resin derived from a biomass material contained in the second layer 30 is a (meth)acrylic resin derived from a biomass material, the environmental load can be reduced while ensuring the physical properties required of the second layer 30 when the second layer 30 is used as the hard coat layer 31.
[0111] For example, the hard coat layer 31, which is the second layer 30, preferably contains a cured product of a curable resin composition such as a thermosetting resin composition or an ionizing radiation-curable resin composition as a main component, and more preferably contains a cured product of an ionizing radiation-curable resin composition as a main component. With respect to the hard coat layer 31, "containing as a main component" means that the hard coat layer 31 contains 50% by mass or more of the resin components constituting the hard coat layer 31. When the hard coat layer 31 contains a cured product of a curable resin composition as a main component, the cured product of the curable resin composition may account for 70% by mass or more, or even 90% by mass or more, of the resin components constituting the hard coat layer 31. Examples of curable resin compositions such as a thermosetting resin composition or an ionizing radiation-curable resin composition include those similar to those exemplified for the first layer 20. The ionizing radiation-curable compound used in the hard coat layer 31 preferably contains a polyfunctional (meth)acrylate compound.
[0112] The lower limit of the thickness of the hard coat layer 31 is preferably 0.5 μm or more, more preferably 1 μm or more. The upper limit of the thickness of the hard coat layer 31 is preferably 30 μm or less, more preferably 10 μm or less. By setting the thickness of the hard coat layer 31 within the above range, it is possible to improve scratch resistance and suppress the occurrence of cracks during processing such as cutting.
[0113] The hard coat layer 31 may further contain additives such as a leveling agent, an antistatic agent, an antioxidant, a surfactant, a dispersant, a light stabilizer, and an ultraviolet absorber.
[0114] <Other Layers> The optical laminate 1 may have other layers such as a high refractive index layer and an antistatic layer. By having a high refractive index layer, the luminous reflectance Y value of the optical laminate 1 can be reduced. The high refractive index layer is preferably located between the resin substrate 10 and the first layer 20. When the above-mentioned second layer 30 is further located between the resin substrate 10 and the first layer 20, the optical laminate 1 preferably includes the resin substrate 10, the second layer 30, the high refractive index layer, and the first layer 20 in this order.
[0115] <High refractive index layer> The high refractive index layer can be formed from a coating liquid for a high refractive index layer containing, for example, a binder resin composition and high refractive index particles. That is, the high refractive index layer preferably contains a binder resin and high refractive index particles.
[0116] The binder resin of the high refractive index layer preferably contains a cured product of a curable resin composition. The ratio of the cured product of the curable resin composition to the total binder resin of the high refractive index layer is preferably 50% by mass or more, more preferably 70% by mass or more, more preferably 90% by mass or more, and most preferably 100% by mass. The curable resin composition of the high refractive index layer includes a heat-curable resin composition or an ionizing radiation-curable resin composition, and an ionizing radiation-curable resin composition is preferred. Examples of curable resin compositions such as a heat-curable resin composition or an ionizing radiation-curable resin composition are the same as those exemplified for the low refractive index layer. The ionizing radiation-curable compound used in the high refractive index layer preferably contains a polyfunctional (meth)acrylate compound.
[0117] Examples of high refractive index particles include antimony pentoxide, zinc oxide, titanium oxide, cerium oxide, tin-doped indium oxide, antimony-doped tin oxide, yttrium oxide, and zirconium oxide.
[0118] The average particle size of the high refractive index particles is preferably 2 nm or more, more preferably 5 nm or more, and even more preferably 10 nm or more. From the viewpoints of whitening prevention and transparency, the average particle size of the high refractive index particles is preferably 200 nm or less, more preferably 100 nm or less, more preferably 80 nm or less, more preferably 60 nm or less, and even more preferably 30 nm or less.
[0119] The lower limit of the content of the high refractive index particles is preferably 100 parts by mass or more, more preferably 150 parts by mass or more, and even more preferably 250 parts by mass or more, relative to 100 parts by mass of the binder resin. The upper limit of the content of the high refractive index particles is preferably 500 parts by mass or less, more preferably 400 parts by mass or less, and even more preferably 350 parts by mass or less, relative to 100 parts by mass of the binder resin.
[0120] The lower limit of the refractive index of the high refractive index layer is preferably 1.53 or more, more preferably 1.54 or more, more preferably 1.55 or more, and still more preferably 1.56 or more. The upper limit of the refractive index of the high refractive index layer is preferably 1.85 or less, more preferably 1.80 or less, more preferably 1.78 or less, and still more preferably 1.77 or less.
[0121] The upper limit of the thickness of the high refractive index layer is preferably 200 nm or less, more preferably 185 nm or less, and even more preferably 175 nm or less. The lower limit of the thickness of the high refractive index layer is preferably 50 nm or more, and more preferably 70 nm or more.
[0122] The high refractive index layer may further contain additives such as a leveling agent, an antistatic agent, an antioxidant, a surfactant, a dispersant, a light stabilizer, and an ultraviolet absorber.
[0123] <Elemental Ratio> In the optical laminate 1 of the present embodiment, the elemental ratio obtained by analyzing the surface region of the optical laminate 1 on the first layer 20 side by X-ray photoelectron spectroscopy preferably satisfies the following condition A. In this specification, "X-ray photoelectron spectroscopy" may be referred to as "XPS." In this specification, the elemental ratio means the average value of measurements at 10 locations.
[0124] <Condition A> The ratio of F element obtained by analyzing the surface region of the optical laminate 1 on the first layer 20 side by X-ray photoelectron spectroscopy is 0.5 atomic % or less.
[0125] By setting the ratio of the F element within the above range, the amount of organic fluorine compounds (PFAS) discharged during the production and disposal of the optical laminate 1 can be reduced. This reduces the environmental impact. The F element whose ratio is obtained by X-ray photoelectron spectroscopy analysis is thought to be F element derived from additives such as binder resin and / or fluorine-based leveling agents. Therefore, the ratio of the F element can be reduced by reducing the amount of fluorine atoms contained in the binder resin 22 and the amount of fluorine atoms contained in additives such as leveling agents. From the perspective of reducing the ratio of the F element, it is preferable that the binder resin 22 does not contain fluorine atoms and that additives such as leveling agents do not contain fluorine atoms.
[0126] When the element ratio satisfies the condition A, the ratio of the F element may be 0.3 atomic % or less, or may be 0.1 atomic % or less.
[0127] In this specification, the surface of the optical laminate 1 on the first layer 20 side means the surface (first surface 1a) of the optical laminate 1 opposite to the resin substrate 10. In this specification, the surface region of the optical laminate 1 on the first layer 20 side means a region up to 80 nm in the thickness direction of the optical laminate 1, when the position of the surface (first surface 1a) is set as a reference position.
[0128] <Pencil hardness> From the viewpoint of improving the scratch resistance of the optical laminate 1, the pencil hardness of the surface (first surface 1a) of the optical laminate 1 on the first layer 20 side is preferably 2H or more, and more preferably 3H or more.
[0129] In this specification, pencil hardness is measured in accordance with JIS K5600-5-4:1999 under conditions of a load of 500 g and a speed of 1.4 mm / sec. Five pencil hardness tests are conducted on a sample for measuring pencil hardness, and the hardness at which no appearance abnormalities such as scratches are observed four or more times is taken as the pencil hardness value of each sample. For example, if five tests are conducted using a 2H pencil and no appearance abnormalities occur four times, the pencil hardness of that sample is 2H. Appearance abnormalities are checked for scratches and dents, excluding discoloration.
[0130] <Luminous reflectance Y value> The luminous reflectance Y value of the optical laminate 1 of the present disclosure, measured from the first layer 20 side at a light incident angle of 5 degrees, is preferably 0.80% or less, more preferably 0.70% or less, and even more preferably 0.65% or less. The luminous reflectance Y value may be 0.34% or less.
[0131] In the present disclosure, the luminous reflectance Y value is measured by the following method. First, a black plate is attached to the surface of the optical laminate 1 on the resin substrate 10 side via a transparent adhesive layer to prepare a sample. Next, light is incident on the sample from the first layer 20 side at an incident angle of 5°, and the luminous reflectance Y value is measured. The light source condition for calculating the reflectance can be a D65 light source. The refractive index difference between the transparent adhesive layer and the member in contact with the transparent adhesive layer of the sample can be within 0.15. The refractive index difference between the transparent adhesive layer and the member in contact with the transparent adhesive layer of the sample can be within 0.10. The refractive index difference between the transparent adhesive layer and the member in contact with the transparent adhesive layer of the sample can be within 0.05. The member in contact with the transparent adhesive layer of the sample can be the resin substrate 10. The black plate can have a total light transmittance of 1% or less according to JIS K7361-1:1997. The black plate can have a total light transmittance of 0% according to JIS K7361-1:1997. The difference in refractive index between the resin constituting the black plate and the transparent adhesive layer can be within 0.15. The difference in refractive index between the resin constituting the black plate and the transparent adhesive layer can be within 0.10. The difference in refractive index between the resin constituting the black plate and the transparent adhesive layer can be within 0.05. In this specification, the luminous reflectance Y value means the average value of measurements taken at 10 locations.
[0132] <Size, Shape, etc.> The optical laminate 1 may be in the form of sheets cut to a predetermined size, or in the form of a roll obtained by winding a long sheet into a roll. The size of the sheets is not particularly limited, but the maximum diameter is approximately 2 inches to 500 inches. The "maximum diameter" refers to the maximum length when any two points on the optical laminate 1 are connected. When the optical laminate 1 is rectangular, the diagonal line of the rectangle is the maximum diameter. When the optical laminate 1 is circular, the maximum diameter is the diameter of the circle. The width and length of the roll are not particularly limited, but generally, the width is approximately 500 mm to 3000 mm and the length is approximately 500 m to 5000 m. The optical laminate 1 in the form of a roll can be cut into sheets to fit the size of an image display device or the like. When cutting, it is preferable to exclude the ends of the roll, which have unstable physical properties. The shape of the sheets is also not particularly limited, and may be, for example, a polygonal shape such as a triangle, a rectangle, or a pentagon, a circular shape, or a random, irregular shape. More specifically, when the optical laminate 1 is rectangular, the aspect ratio is not particularly limited as long as it does not cause any problems as a display screen. For example, the aspect ratio may be 1:1, 4:3, 16:10, 16:9, 2:1, etc.
[0133] <Optical Properties> The optical laminate 1 has a total light transmittance of 70% or more and a haze of 2.0% or less.
[0134] In this specification, the total light transmittance is measured in accordance with JIS K7361-1:1997. The total light transmittance of the optical laminate 1 is more preferably 80% or more, and even more preferably 85% or more. The light incident surface when measuring the total light transmittance and haze is the surface (second surface 1b) opposite to the surface on the first layer 20 side. In this specification, the total light transmittance and haze refer to the average values of measurements taken at 10 locations.
[0135] In this specification, haze is measured in accordance with JIS K7136:2000. The haze of the optical laminate 1 is more preferably 1.0% or less, more preferably 0.7% or less, and even more preferably 0.5% or less. By setting the upper limit of the haze of the optical laminate 1 as described above, when the optical laminate 1 is used in an image display device as described below, the resolution of the image viewed through the optical laminate 1 can be increased. The lower limit of the haze is, for example, 0.1% or more. An optical laminate 1 having a haze of 0.1% or more is considered to be sufficiently filled with the adsorbent particles 21. With such an optical laminate 1, it is considered that the effect of the adsorbent particles 21 can be fully obtained.
[0136] <Function of Optical Laminate> The optical laminate 1 of the present embodiment includes a first layer 20 containing adsorbent particles 21. It is believed that the adsorbent particles 21 thereby adsorb odor components released from the resin derived from the biomass material, thereby suppressing the generation of odor.
[0137] The present inventors have conducted extensive research into an optical laminate 1 capable of suppressing odor generation and have found that an optical laminate 1 including a first layer 20 containing adsorbent particles 21 can effectively suppress odor generation when the optical laminate 1 has a haze of 2.0% or less. Further research is needed to fully elucidate the reason for this, but the following reason is thought to be the case. In the optical laminate 1 of this embodiment, the resin substrate 10 contains a resin derived from a biomass material. Odor components released from the biomass material-derived resin contained in the resin substrate 10 come into contact with the adsorbent particles 21 as they move toward the first surface 1a, and are adsorbed by the adsorbent particles 21. This suppresses the release of odor components into the air via the first surface 1a, thereby suppressing odor generation. It is believed that the odor components come into contact with and are adsorbed by the adsorbent particles 21 as they move through the regions formed in the gaps between the adsorbent particles 21 within the first layer 20, where the binder resin 22 is present. For this reason, if the first layer 20 has a portion where the gaps between the adsorbent particles 21 are small, such as a portion where the adsorbent particles 21 are excessively aggregated, odor components are unlikely to migrate to that portion. In a portion where the gaps between the adsorbent particles 21 are small, odor components are unlikely to migrate in the first place, and therefore the adsorbent particles 21 are unlikely to adsorb the odor components. In contrast, if the adsorbent particles 21 are more uniformly arranged in the first layer 20 and the size of the gaps between the adsorbent particles 21 is ensured to be equal to or larger than a certain size, odor components can be brought into contact with many of the adsorbent particles 21 present in the first layer 20. For this reason, odor components can be more effectively adsorbed in the first layer 20 where the adsorbent particles 21 are more uniformly arranged than in a portion where the gaps between the adsorbent particles 21 are small. If the first layer 20 has a portion where the gaps between the adsorbent particles 21 are small, such as a portion where the adsorbent particles 21 are excessively aggregated, the haze of the optical laminate 1 including the first layer 20 will be large. On the other hand, if the adsorbent particles 21 are arranged more uniformly and the size of the gaps between the adsorbent particles 21 is secured to be at least a certain size, the haze will be smaller.In an optical laminate 1 having a haze of 2.0% or less, it is believed that the size of the gaps between the adsorbent particles 21 is secured to a certain extent so that odor components can be effectively adsorbed. For the above reasons, it is believed that when an optical laminate 1 including a first layer 20 containing adsorbent particles 21 has a haze of 2.0% or less, it can effectively suppress the generation of odor.
[0138] By increasing the particle diameter of the adsorbent particles 21, more odor components can be adsorbed by the adsorbent particles 21. For example, if the adsorbent particles 21 are hollow particles, increasing the particle diameter of the hollow particles can increase the volume of the cavities of the hollow particles where odor components are captured. If the adsorbent particles 21 are porous particles, increasing the particle diameter of the porous particles can increase the volume of the pores of the porous particles where odor components are captured. As described above, whether the adsorbent particles 21 are hollow particles or porous particles, increasing the particle diameter of the adsorbent particles 21 can cause the adsorbent particles 21 to adsorb more odor components. Furthermore, when the first layer 20 functions as a low refractive index layer, increasing the particle diameter of the adsorbent particles 21 can increase the volume of the voids in the adsorbent particles 21. This can further reduce the refractive index of the first layer 20. Therefore, from the viewpoint of more effectively adsorbing odor components and suppressing odor generation by the adsorbent particles 21, and from the viewpoint of lowering the refractive index of the first layer 20, it is considered preferable to use adsorbent particles 21 with a large particle size. On the other hand, when adsorbent particles 21 with a large particle size are used, the gaps between the adsorbent particles 21 tend to be particularly large. If the gaps between the adsorbent particles 21 are particularly large, odor components may easily pass through the first layer 20 through the gaps, making it difficult to suppress odor generation. Furthermore, the gaps are filled with binder resin 22. It is also possible that the refractive index of the first layer 20 cannot be significantly lowered due to the binder resin 22 present in the gaps. In consideration of the above-mentioned problems, the present inventors have conceived of using two or more types of adsorbent particles 21 with different particle sizes, as described above. In particular, in this embodiment, the adsorbent particles 21 may include large particles with a particle diameter of 90.0 nm or more and small particles with a particle diameter of less than 90.0 nm. In particular, the proportion of the mass of the adsorbent particles 21 having a particle diameter of 90.0 nm or more to the total mass of the adsorbent particles 21 contained in the first layer 20 may be 30% or more. The proportion of the mass of the adsorbent particles 21 having a particle diameter of 90.0 nm or more to the total mass of the adsorbent particles 21 contained in the first layer 20 may be 80% or less.With such adsorbent particles 21, the gaps between the adsorbent particles 21 are smaller than those with only large particles. By using large particles with large particle diameters as the adsorbent particles 21 while also using small particles to prevent the gaps between the adsorbent particles 21 from becoming too large, the adsorbent particles 21 can more effectively adsorb odor components and suppress the generation of odors. Furthermore, the adsorbent particles 21 can more effectively reduce the refractive index of the first layer 20.
[0139] As described above, the adsorptive particles 21 containing large particles can more effectively reduce the refractive index of the first layer 20. In particular, the adsorptive particles 21 containing large particles can sufficiently reduce the refractive index of the first layer 20 without including the above-mentioned additive containing fluorine atoms in the first layer 20. This makes it possible to reduce the environmental load during the production and disposal of the optical laminate 1 while sufficiently reducing the refractive index of the first layer 20.
[0140] As described above, from the viewpoint of moving odor components within the first layer 20 and bringing them into contact with a larger number of adsorbent particles 21 for adsorption, it is preferable that the gaps between the adsorbent particles 21 be large. On the other hand, from the viewpoint of preventing odor components from passing through the first layer 20 through the gaps between the adsorbent particles 21, it is preferable that the gaps between the adsorbent particles 21 be small. From the viewpoint of more effectively suppressing odor generation, it is necessary that the gaps between the adsorbent particles 21 are not too large or too small. Furthermore, from the viewpoint of avoiding a significant decrease in the refractive index of the first layer 20 due to the presence of the binder resin 22 in the gaps between the adsorbent particles 21, it is also necessary that the gaps between the adsorbent particles 21 are not too large. In the optical laminate 1 of the present embodiment, in consideration of the above-mentioned problems, the size of the gaps between the adsorbent particles 21 is adjusted to be not too large or too small by, for example, using two or more types of adsorbent particles 21 with different particle diameters.
[0141] As described above, the average La of the distance w1 between the centers of gravity of the adsorbent particles 21 represents the degree of density of the adsorbent particles 21. When the average La is small, the degree of density of the adsorbent particles 21 increases, and the gaps between the adsorbent particles 21 become smaller. When the average La is large, the degree of density of the adsorbent particles 21 decreases, and the gaps between the adsorbent particles 21 become larger. As described above, the average La is preferably 90 nm or more and 130 nm or less, and more preferably 110 nm or more and 120 nm or less. When the average La is within the above numerical range, the size of the gaps between the adsorbent particles 21 becomes a size that can more effectively suppress the generation of odor. Furthermore, when the average La is within the above numerical range, the size of the gaps between the adsorbent particles 21 becomes a size that can more effectively reduce the refractive index of the first layer 20.
[0142] Furthermore, as described above, the value Lσ / La obtained by dividing the standard deviation Lσ of the distance w1 between the centers of gravity of the adsorbent particles 21 by the average La represents the degree of variation in the distribution of the adsorbent particles 21. In particular, Lσ / La represents the degree of variation in the distribution of the positions of the centers of gravity of the adsorbent particles 21. The smaller Lσ / La, the more uniform the distribution of the centers of gravity of the adsorbent particles 21, and the larger Lσ / La, the more non-uniform the distribution of the centers of gravity of the adsorbent particles 21. Here, when two or more types of adsorbent particles 21 with different particle diameters are used, the degree of variation in the distribution of the positions of the centers of gravity of the adsorbent particles 21 is considered to be greater than a certain level compared to when adsorbent particles 21 with a uniform particle diameter are used. On the other hand, if the gaps between the adsorbent particles 21 are adjusted to an appropriate numerical range taking into consideration the suppression of odor generation and the reduction of the refractive index of the first layer 20, the degree of variation in the distribution of the positions of the centers of gravity of the adsorbent particles 21 is considered to be smaller than a certain level. As described above, Lσ / La is preferably 0.11 or more and 0.30 or less, and more preferably 0.16 or more and 0.23 or less. When Lσ / La is within the above numerical range, it is considered that the gaps between the adsorbent particles 21 can be adjusted to an appropriate numerical range by using two or more types of adsorbent particles 21 with different particle diameters, for example.
[0143] In particular, when the optical laminate 1 has a haze of 2.0% or less and Lσ / La is within the above numerical range, it is considered that the adsorbent particles 21 are arranged sufficiently uniformly, the gaps between the adsorbent particles 21 are also adjusted sufficiently uniformly, and the size of the gaps between the adsorbent particles 21 is sufficiently secured. Therefore, when the optical laminate 1 has a haze of 2.0% or less and Lσ / La is within the above numerical range, the generation of odor can be more effectively suppressed.
[0144] Furthermore, when the average La is within the above numerical range and Lσ / La is within the above numerical range, it is considered that the adsorbent particles 21 are arranged sufficiently uniformly, the gaps between the adsorbent particles 21 are also adjusted sufficiently uniformly, and the size of the gaps between the adsorbent particles 21 is sufficiently secured. Therefore, when the average La is within the above numerical range and Lσ / La is within the above numerical range, the generation of odors can be more effectively suppressed.
[0145] According to the optical laminate 1 of this embodiment, not only can the adsorbent particles 21 absorb odor components from the layers that constitute the optical laminate 1, such as the resin substrate 10, but also the adsorbent particles 21 can absorb odor components that are present outside the optical laminate 1. Therefore, according to the optical laminate 1 of this embodiment, odors generated outside the optical laminate 1 can be reduced.
[0146] [Polarizing Plate] As an example, the optical laminate 1 of the present embodiment functioning as an anti-reflection member can be incorporated into a polarizing plate. An example of a polarizing plate in this case will be described. The polarizing plate includes a polarizer having a polarizer first surface and a polarizer second surface, a first transparent protective plate arranged on the polarizer first surface side of the polarizer, and a second transparent protective plate arranged on the polarizer second surface side of the polarizer. The polarizer second surface is the surface of the polarizer opposite to the polarizer first surface. At least one of the first transparent protective plate and the second transparent protective plate is the optical laminate 1 of the present embodiment described above. Either one of the first transparent protective plate and the second transparent protective plate may be the optical laminate 1 of the present embodiment described above. The optical laminate 1 is arranged so that the surface on the first layer 20 side (first surface 1a) faces away from the polarizer.
[0147] The polarizing plate is used, for example, in combination with a λ / 4 retardation plate to impart anti-reflection properties. When the polarizing plate is disposed in an image display device, the λ / 4 retardation plate is disposed on the display element of the image display device, and the polarizing plate is disposed closer to the viewer than the λ / 4 retardation plate. When the polarizing plate is for a liquid crystal display device, the polarizing plate is used to impart a liquid crystal shutter function. In this case, the liquid crystal display device is disposed in the following order from the backlight side: lower polarizing plate, liquid crystal display element, and upper polarizing plate. The lower polarizing plate and upper polarizing plate are disposed so that the absorption axis of the polarizer of the lower polarizing plate is perpendicular to the absorption axis of the polarizer of the upper polarizing plate. In the liquid crystal display device, the polarizing plate of the present embodiment can be used as the upper polarizing plate and the lower polarizing plate. In the liquid crystal display device, it is preferable to use the polarizing plate of the present embodiment as the upper polarizing plate. When the polarizing plate of the present embodiment is used as the upper polarizing plate of the liquid crystal display device, it is preferable to use the optical laminate 1 of the present embodiment as a transparent protective plate on the light exit surface side of the polarizer. When the polarizing plate of this embodiment is used as the lower polarizing plate of the liquid crystal display device, it is preferable to use the optical laminate 1 of this embodiment as a transparent protective plate on the light incident surface side of the polarizer.
[0148] <Transparent Protective Plate> The polarizing plate of the present embodiment includes the above-described optical laminate 1 of the present embodiment as at least one of the first transparent protective plate and the second transparent protective plate. In the polarizing plate of the present embodiment, it is more preferable that both the first transparent protective plate and the second transparent protective plate include the above-described optical laminate 1 of the present embodiment.
[0149] When one of the first transparent protective plate and the second transparent protective plate includes the optical laminate 1 of the present embodiment described above, the other transparent protective plate is, for example, a transparent protective plate having optical isotropy. In this specification, having optical isotropy refers to an in-plane retardation of 20 nm or less. The in-plane retardation of a transparent protective plate having optical isotropy is preferably 10 nm or less, more preferably 5 nm or less. From the viewpoint of imparting optical isotropy to the transparent protective plate, the material of the transparent protective plate is preferably an acrylic film or a triacetyl cellulose (TAC) film. When one of the first transparent protective plate and the second transparent protective plate includes the optical laminate 1 of the present embodiment described above, it is preferable that the transparent protective plate on the light emission side includes the optical laminate 1 of the present embodiment described above.
[0150] <Polarizer> Examples of polarizers that can be used include sheet-type polarizers such as polyvinyl alcohol films, polyvinyl formal films, polyvinyl acetal films, and saponified ethylene-vinyl acetate copolymer films that are dyed with iodine or the like and stretched; wire-grid polarizers made of a large number of metal wires arranged in parallel; coated polarizers coated with a lyotropic liquid crystal or a dichroic guest-host material; and multilayer thin-film polarizers. The polarizer may be a reflective polarizer that has the function of reflecting polarized light components that are not transmitted.
[0151] [Image Display Panel] As an example, the optical laminate 1 of the present embodiment functioning as an anti-reflection member can be incorporated into an image display panel 100. An example of the image display panel 100 in this case will be described. The image display panel 100 of the present embodiment is an image display panel 100 having a display element 40 and an optical film arranged on the light emission surface side of the display element 40. The image display panel 100 includes the optical laminate 1 of the present embodiment described above as the optical film. The optical laminate 1 is arranged so that the surface on the first layer 20 side (first surface 1a) faces the opposite side to the display element 40. The optical laminate 1 is arranged on the outermost surface of the image display panel 100 (see FIG. 3).
[0152] The display element 40 may be a liquid crystal display element, an EL display element such as an organic EL display element or an inorganic EL display element, a plasma display element, or the like. An LED display element such as a micro LED display element may also be used as the display element 40. The display element 40 may have an internal touch panel function. Examples of the liquid crystal display system of the liquid crystal display element include the IPS system, VA system, multi-domain system, OCB system, STN system, and TSTN system.
[0153] The image display panel 100 of the present embodiment may be an image display panel with a touch panel having a touch panel between the display element 40 and the optical laminate 1. In this case, the optical laminate 1 may be disposed on the outermost surface of the image display panel with a touch panel, and the surface of the optical laminate 1 on the first layer 20 side may be disposed so as to face the opposite side to the display element 40.
[0154] The size of the image display panel 100 is not particularly limited, but the maximum diameter is about 2 inches to 500 inches. The maximum diameter means the maximum length when connecting any two points on the surface of the image display panel 100.
[0155] [Image display device] Next, an image display device of the present embodiment will be described. The image display device includes a display element 40 and the optical laminate 1 of the present embodiment described above, which is disposed on the display element 40. As an example, the image display panel 100 described above can be incorporated into the image display device. By incorporating the image display panel 100 into the image display device, the image display device will include the display element 40 and the optical laminate 1. An example of the image display device in this case will be described. The image display device of the present embodiment includes the image display panel 100 of the present embodiment described above. The optical laminate 1 is disposed on the outermost surface of the image display device.
[0156] The image display device of this embodiment preferably further includes a drive control unit electrically connected to the image display panel 100, and a housing that houses the image display panel 100, the drive control unit, etc. When the display element is a liquid crystal display element, the image display device of this embodiment requires a backlight. The backlight is disposed on the side opposite to the light-emitting surface of the liquid crystal display element.
[0157] The size of the image display device is not particularly limited, but the maximum diameter of the effective display area of the image display device may be approximately 2 inches or more and 500 inches or less. The effective display area of an image display device is the area in which an image can be displayed. For example, if the image display device has a housing that surrounds the display element, the area inside the housing is the effective display area. The maximum diameter of the effective display area refers to the maximum length when any two points within the effective display area are connected. For example, if the effective display area is rectangular, the diagonal of the rectangle is the maximum diameter. If the effective display area is circular, the diameter of the circle is the maximum diameter.
[0158] [Front Panel] Next, the front panel of this embodiment will be described. The front panel is a front panel for an image display device. The front panel comprises a plate-like member that is a resin plate or a glass plate, and the optical laminate 1 of this embodiment described above, which is arranged on the plate-like member. In the front panel, the optical laminate 1 is arranged so that the surface on the first layer 20 side (first surface 1a) faces away from the plate-like member. The front panel of this embodiment can be incorporated into an image display device. In this case, the image display device may comprise a display element 40 and a front panel arranged on the light emission surface side of the display element 40.
[0159] [Anti-reflective article] As an example, the optical laminate 1 of the present embodiment that functions as an anti-reflective member can be incorporated into an anti-reflective article. An example of an anti-reflective article in this case will be described. The anti-reflective article of the present embodiment has an article and the optical laminate 1 of the present embodiment described above that is disposed on the article. The optical laminate 1 is disposed so that the surface on the first layer 20 side (first surface 1a) faces away from the article. The optical laminate 1 is disposed on the outermost surface of the anti-reflective member. The article and the optical laminate 1 are preferably laminated via an adhesive layer.
[0160] Examples of articles that constitute anti-reflective articles include instrument panels, clocks, showcases, show windows, and windows. The members may be transparent or opaque, and there is no particular limitation on the color tone.
[0161] Next, specific examples of the above-mentioned embodiment and each modification will be described. "Parts" and "%" are based on mass unless otherwise specified.
[0162] 1. Measurement and Evaluation Measurement and evaluation were performed on the optical laminates of the Examples and Comparative Examples as follows. The atmosphere during each measurement and evaluation was a temperature of 23±5°C and a relative humidity of 40% to 65%. Before starting each measurement and evaluation, the target sample was exposed to the atmosphere for 30 minutes to 60 minutes, and then measurement and evaluation were performed. The samples used for each measurement and evaluation were prepared by cutting the optical laminates of the Examples and Comparative Examples. The cutting locations were selected from random locations after visually checking that there were no abnormalities such as dust or scratches.
[0163] 1-1. Refractive Index Difference For the optical laminates of the Examples and Comparative Examples, the theoretical values of the refractive index of the first layer and the second layer were calculated. Using the calculated theoretical values, the theoretical value of the refractive index difference between the first layer and the second layer was calculated. The theoretical value of the refractive index difference was calculated by subtracting the theoretical value of the refractive index of the first layer from the theoretical value of the refractive index of the second layer.
[0164] Specifically, the theoretical value of the refractive index of the first layer was calculated by the following method. A coating liquid for the first layer, which will be described later and which is used to prepare the optical laminate in each of the Examples and Comparative Examples, was applied to a 50 μm-thick PET substrate that had not been subjected to an easy-adhesion treatment. The solvent was then evaporated by drying at 40° C. for 60 seconds (drying air speed: 20 m / s). Subsequently, the first layer was dried in a nitrogen atmosphere with an oxygen concentration of 200 ppm or less, with an integrated light intensity of 200 mJ / cm. 2A layer corresponding to the first layer was formed by irradiating the sample with ultraviolet light at 1000 W at 1000 W. The thickness of the layer was 1 μm or more and 3 μm or less. This resulted in a first laminate consisting of a PET substrate and a layer corresponding to the first layer. The first laminate was cut into 5 cm x 5 cm pieces. A sample was prepared by bonding the PET substrate side of the cut first laminate to a black plate (manufactured by Kuraray Co., Ltd., product name: COMOGLAS DFA2CG 502K (black), 2 mm thick) via an optically transparent adhesive sheet (Panac Corporation, product name: Panaclean PD-S1). When the perpendicular direction to the surface of the layer corresponding to the first layer of the sample was set to 0 degrees, light was incident on the sample from a direction of 5 degrees, and the reflectance of the first layer was measured based on the specular reflection of the incident light. The reflectance of the first layer was measured at 0.5 nm intervals for light of different wavelengths in the wavelength range of 380 nm to 780 nm, and the average reflectance R (%), which is the average value of the reflectances of the light of the different wavelengths, was calculated. The measurement device used was a spectral reflectance meter (manufactured by Shimadzu Corporation, product name: UV-2600). The theoretical value n of the refractive index of the first layer was calculated from the average reflectance R of the first layer using the following equation (1):
[0165] Furthermore, the theoretical value of the refractive index of the second layer was calculated by the following method. A coating solution for the second layer, which will be described later and which is used to prepare the optical laminate in each of the Examples and Comparative Examples, was applied to a 50 μm-thick PET substrate that had not been subjected to an easy-adhesion treatment. The coating solution was then dried at 70° C. for 1 minute to volatilize the solvent. Subsequently, the coating solution was dried in a nitrogen atmosphere with an oxygen concentration of 200 ppm or less, with an integrated light intensity of 100 mJ / cm. 2 A layer corresponding to the second layer was formed by irradiating the PET substrate with ultraviolet light at a wavelength of 1 μm or more and 3 μm or less. This resulted in a second laminate in which the PET substrate and the layer corresponding to the second layer were stacked. The theoretical refractive index of the second layer was calculated from the second laminate using the same method as that used to calculate the theoretical refractive index of the first layer from the first laminate.
[0166] From the theoretical refractive index of the first layer and the theoretical refractive index of the second layer calculated by the above-mentioned method, a value was calculated by subtracting the theoretical refractive index of the first layer from the theoretical refractive index of the second layer.
[0167] 1-2. Measurement of La, Lσ, and Lσ / La For the optical laminates of the Examples and Comparative Examples, the average distance between the centers of gravity of the adsorbent particles in the first layer, La, the standard deviation Lσ of the distance between the centers of gravity of the adsorbent particles in the first layer, and Lσ / La, the value obtained by dividing the standard deviation Lσ by the average La, were measured. The measurements were carried out in steps (1) to (5) of the specification. The scanning electron microscope (SEM) used in (1) was an SU9000 product name by Hitachi High-Technologies Corporation, and the acceleration voltage was 30 kV. The version of ImageJ used in (2) was 1.54f.
[0168] 1-3. Sensory Evaluation of Odor Samples were prepared by cutting the optical laminates of the Examples and Comparative Examples into 10 cm x 10 cm pieces. Glass was attached to the surface (second surface) of each sample opposite to the surface on the first layer side. The samples were placed in an aluminum pouch bag, sealed, and left for 3 days. After leaving the sample, 20 subjects smelled the contents of the pouch bag and evaluated whether they could detect an odor. Based on the subjects' evaluations, the samples were ranked according to the following criteria: AA: 19 or more subjects rated that no odor was detected. A: 15 to 18 subjects rated that no odor was detected. B: 8 to 14 subjects rated that no odor was detected. C: 8 to 14 subjects rated that no odor was detected. D: 7 or fewer subjects rated that no odor was detected.
[0169] 1-4. Environmental contribution (presence or absence of fluorine atoms) The optical laminates of the examples and comparative examples were evaluated for their environmental contribution (presence or absence of fluorine atoms). Specifically, it was evaluated whether the optical laminate contained a material containing fluorine atoms. Based on the above evaluation, the samples were ranked according to the following criteria: A: The optical laminate did not contain a material containing fluorine atoms. B: The optical laminate contained a material containing fluorine atoms.
[0170] 1-5. Environmental contribution (whether or not resin substrate contains resin derived from biomass material) The optical laminates of the examples and comparative examples were evaluated for environmental contribution based on whether or not the resin substrate contained a resin derived from biomass material. Based on the above evaluation, the samples were ranked according to the following criteria. A: The resin substrate contained a resin derived from biomass material. B: The resin substrate did not contain a resin derived from biomass material.
[0171] 1-6. Overall Evaluation of Sensory Evaluation of Odor and Environmental Contribution Based on the evaluation results of the three items described above, "1-3. Sensory Evaluation of Odor," "1-4. Environmental Contribution (Whether Fluorine Atoms Are Contained)," and "1-5. Environmental Contribution (Whether the Resin Base Material Contains a Resin Derived from Biomass Materials)," a sensory evaluation of odor and an overall evaluation of environmental contribution were conducted. Based on the above evaluations, the samples were ranked according to the following criteria. If there was one "D" in the evaluation results of the three items, or if all of the evaluation results of the three items were either "B" or "C," the overall evaluation result was rated as "C." For samples whose overall evaluation result did not fall under "C," if there was one or more "C" in the evaluation results of the three items, or if the evaluation results of two of the three items were "B," the overall evaluation result was rated as "B." For samples whose overall evaluation result did not fall under either "B" or "C," if there was one or more "B" in the evaluation results of the three items, the overall evaluation result was rated as "A." For samples whose overall evaluation result did not fall into any of "B," "C," and "A," the overall evaluation result was given an "AA."
[0172] 1-7. Total Light Transmittance (Tt) and Haze (Hz) The optical laminates of the Examples and Comparative Examples were cut into 10 cm x 10 cm pieces to prepare samples for measurement. Using a haze meter (HM-150, manufactured by Murakami Color Research Laboratory), the total light transmittance of each sample according to JIS K7361-1:1997 and the haze according to JIS K7136:2000 were measured under the following conditions. In order to stabilize the light source, the power switch of the device was turned on in advance, and then calibration was performed 15 minutes or more later, without setting anything in the entrance opening where the measurement sample was to be placed. Thereafter, the measurement sample was set in the entrance opening, and the total light transmittance and haze were measured. The light incident surface during measurement was the resin substrate side.
[0173] 1-8. Moisture permeability The moisture permeability of the optical laminates of the Examples and Comparative Examples was measured by the following method. The amount of water vapor (g / (m)) passing through the protective film in 24 hours was measured in an atmosphere at a temperature of 40°C and a relative humidity of 90% using a method in accordance with the moisture permeability test method (cup method) described in JIS Z0208:1976. 2 The amount of water vapor was measured three times, and the arithmetic mean value of the values obtained was taken as the moisture permeability.
[0174] 1-9. Scratch Resistance <Run-in> A polyethylene terephthalate film (thickness 100 μm) was attached to the measurement stage of a measuring device (SAM JEE TECK, product name "SJTR-053"). Next, steel wool (#0000, product name "Bonstar B-204" by Nippon Steel Wool Co., Ltd.) was set. The steel wool was brought into contact with the surface of the polyethylene terephthalate film, and the steel wool was moved back and forth 10 times under the conditions of a load of 500 g, a movement speed of 100 mm / sec, and a movement distance of 170 mm per reciprocation. The contact area between the steel wool and the polyethylene terephthalate film was 4 cm. 2<Main Measurement> Samples were prepared by cutting the optical laminates of the Examples and Comparative Examples into 3 cm x 25 cm pieces. The cutting locations were selected from random locations after visually checking for any abnormalities such as dust or scratches. The samples were placed on the measurement stage of the measurement device with the first layer side facing up. The steel wool was brought into contact with the surface of the first layer, and the steel wool was moved back and forth 10 times under the conditions of a load of 350 g, a moving speed of 4500 mm / min, and a moving distance of 170 mm per reciprocation. The contact area between the steel wool and the sample was 4 cm 2 Next, under a bright room environment of 1300 Lux to 1700 Lux, the number of scratches 1 cm or longer was visually checked and ranked according to the following criteria. However, as mentioned above, scratches less than 1 cm in length were not counted as scratches. Also, of the 170 mm movement distance of the steel wool, the movement speed was not uniform in the region 30 mm from each end. For this reason, of the 170 mm movement distance of the steel wool, scratches were not counted in the region 30 mm from each end. A: Number of scratches: 0 B: Number of scratches: 1 to 4 C: Number of scratches: 5 to 14 D: Number of scratches: 15 or more
[0175] 1-10. Pencil Hardness Samples were prepared by cutting the optical laminates of the Examples and Comparative Examples into pieces measuring 5 cm x 10 cm. The pencil hardness of the first layer side of each sample was measured in accordance with JIS K5600-5-4:1999 under conditions of a load of 500 g and a speed of 1.4 mm / sec. A pencil hardness tester (product number: NP-type pencil scratch coating hardness tester) manufactured by Toyo Seiki Seisakusho was used for the measurement. Both ends of the cut sample were attached to the base of the pencil hardness tester using mending tape (3M, product number "810-3-18"). Five pencil hardness tests were performed, and the hardness at which no appearance abnormalities such as scratches were observed four or more times was recorded as the pencil hardness value of each sample. For example, if five tests were performed using a 2H pencil and no appearance abnormalities were observed four times, the pencil hardness of the antiglare laminate was recorded as 2H. Regarding appearance abnormalities, scratches and dents were checked, but discoloration was not included. A pencil hardness of 2H or more was considered to be acceptable.
[0176] 1-11. XPS Analysis Measurement samples were cut out from the optical laminates of the Examples and Comparative Examples. Using an X-ray photoelectron spectrometer, the X-ray photoelectron spectra of the C1s orbital, O1s orbital, Si2p orbital, and F1s orbital on the surface of the first layer of each measurement sample were measured under the conditions described below. Peak separation was performed on each X-ray photoelectron spectrum to determine the ratio of F element to all elements. <Measurement> Apparatus: "AXIS-NOVA" manufactured by Shimadzu Corporation X-ray source: AlKα X-ray output: 150 W Emission current: 10 mA Acceleration voltage: 15 kV Measurement area: 300 × 700 μm Charge neutralization mechanism: ON Pass energy (when measuring narrow spectrum): 40 eV
[0177] 1-12. Foldability The foldability of the optical laminates of the Examples and Comparative Examples was evaluated by the following folding test. Strip-shaped samples measuring 30 mm in short side (TD) x 100 mm in long side (MD) were cut out from the optical laminates obtained in the Examples and Comparative Examples. Both ends of the short side (30 mm) of the sample were fixed (a region 10 mm from the tip was fixed) to a durability testing machine (product name "DLDMLH-FS", Yuasa System Equipment Co., Ltd.), and a continuous folding test was performed by folding the sample 180 degrees 200,000 times. The folding speed was 120 times per minute. The foldability of the optical laminates was evaluated based on the following evaluation criteria: A: No cracks or breaks in the bent portion even when the distance φ between the two sides was 2 mm. B: Cracks or breaks in the bent portion when the distance φ between the two sides was 2 mm, but no cracks or breaks in the bent portion when the distance φ was 3 mm. C: When the distance φ between the two sides is 3 mm, cracks or breaks occur at the bent portion.
[0178] The details of the folding test are as follows. As shown in FIG. 4A , in the continuous folding test, first, side portion 100C of optical laminate 1 and side portion 100D opposite side portion 100C are fixed by fixing portions 600 arranged in parallel. Fixing portions 600 are slidable horizontally. Next, as shown in FIG. 4B , fixing portions 600 are moved closer to each other to deform optical laminate 1 so as to fold it. Furthermore, as shown in FIG. 4C , fixing portions 600 are moved to a position where the distance φ between the two opposing side portions of optical laminate 1 fixed by fixing portions 600 is 2 mm or 3 mm, and then fixing portions 600 are moved in the opposite direction to eliminate the deformation of optical laminate 1. By moving fixing portions 600 as shown in FIGS. 4A to 4C , optical laminate 1 can be folded 180 degrees. Furthermore, by conducting a continuous folding test so that the bent portion 100E of the optical laminate 1 does not protrude from the lower end of the fixed portion 600, and by controlling the distance φ when the fixed portion 600 is closest to the optical laminate to 2 mm or 3 mm, the distance φ between the two opposing sides of the optical laminate can be set to 2 mm or 3 mm.
[0179] 1-13. Luminous Reflectance Y Value The optical laminates of the Examples and Comparative Examples were cut into 5 cm x 5 cm pieces. A sample was prepared by bonding the resin substrate side of the cut optical laminate to a black plate (manufactured by Kuraray Co., Ltd., product name: COMOGLAS DFA2CG 502K (black), 2 mm thick) measuring 5 cm x 5 cm via an optically transparent adhesive sheet (Panac Corporation, product name: Panaclean PD-S1). When the perpendicular direction to the surface of the first layer side of the sample was set to 0 degrees, light was incident on the sample from a direction of 5 degrees, and the luminous reflectance Y value of the sample was measured based on the specular reflection of the incident light. A spectral reflectance meter (manufactured by Shimadzu Corporation, product name: UV-2600) was used as the measuring device. The measuring device measured reflectance at 0.5 nm intervals over a wavelength range of 380 nm to 780 nm, and then converted to lightness perceived by the human eye using software. The software was the software built into the measuring device, and was used to calculate the reflectance under the conditions that the light source was D65 and the viewing angle was 2 degrees.
[0180] 2. Preparation of Optical Laminate [Example 1] An 80 μm thick film of polyethylene terephthalate derived from biomass material was prepared as a resin substrate. Subsequently, a coating solution 1 for the second layer having the following formulation was applied onto the resin substrate. The coating solution was then dried at 70° C. for 1 minute to volatilize the solvent. Subsequently, the optical laminate was exposed to light with an integrated light intensity of 100 mJ / cm in a nitrogen atmosphere with an oxygen concentration of 200 ppm or less. 2 The first layer was then coated with UV light at a dry thickness of 10 μm to form a hard coat layer as the second layer. Coating Solution 1 for the first layer, having the following formulation, was then applied onto the second layer. The solvent was then evaporated by drying at 40°C for 60 seconds (drying air speed: 20 m / s). The coating was then irradiated with UV light at an integrated dose of 200 mJ / cm in a nitrogen atmosphere with an oxygen concentration of 200 ppm or less. 2 A low refractive index layer having a dry thickness of 100 nm was formed as a first layer by irradiating the coated layer with ultraviolet light at a rate of 100 nm, thereby obtaining an optical laminate of Example 1.
[0181] <Coating liquid 1 for second layer> Glycerin triacrylate 15 parts by mass (Toagosei Co., Ltd., product name "M-930") High refractive index acrylate 25 parts by mass Photopolymerization initiator 1.6 parts by mass (IGM Resins, product name "Omnirad 127") Silicone leveling agent 0.1 parts by mass (Kyoeisha Chemical Co., Ltd., product name "LE-304") 58.3 parts by mass of a mixture of methyl isobutyl ketone and propylene glycol dimethyl ether in a ratio of 8:2
[0182] <Coating Solution 1 for First Layer> Pentaerythritol triacrylate (PETA) 100 parts by mass Adsorbent particles 140 parts by mass (average particle diameter 65 nm, hollow silica particles surface-treated with a silane coupling agent having a methacryloyl group) Solid particles 25 parts by mass (average particle diameter 12 nm, solid silica particles) Leveling agent 3.0 parts by mass (manufactured by Shin-Etsu Chemical Co., Ltd., trade name "KP-420") Photopolymerization initiator 3.5 parts by mass (manufactured by IGM Resins, trade name "Omnirad 127") Methyl ethyl ketone 20 parts by mass Methyl isobutyl ketone 30 parts by mass Propylene glycol monomethyl ether acetate 40 parts by mass
[0183] Examples 2 to 14 Optical laminates of Examples 2 to 14 were obtained in the same manner as in Example 1, except that the formulation of the coating liquid for the first layer was changed to the formulation shown in Table 1.
[0184] Comparative Example 1 An optical laminate of Comparative Example 1 was obtained in the same manner as in Example 1, except that the first layer was not formed on the second layer.
[0185] [Comparative Example 2] A polyethylene terephthalate film newly synthesized from petroleum, having a thickness of 80 μm, was prepared as a resin substrate. The formulation of the coating liquid for the first layer was changed to the formulation shown in Table 1. An optical laminate of Comparative Example 2 was obtained in the same manner as in Example 1, except for the above points.
[0186] Comparative Example 3 The formulation of the coating liquid for the first layer was changed to the formulation shown in Table 1. An optical layered body of Comparative Example 3 was obtained in the same manner as in Example 1 except for the above points.
[0187] The "Refractive Index" column of the "First Layer" in Table 1 shows the calculated theoretical value of the refractive index of the first layer. The "Amount of Hollow Silica Particles, Particle Diameter 100 nm" column of the "First Layer" in Table 1 shows the amount of hollow silica particles with an average particle diameter of 100 nm that have been surface-treated with a silane coupling agent having a methacryloyl group. The "Amount of Hollow Silica Particles, Particle Diameter 75 nm" column of the "First Layer" in Table 1 shows the amount of hollow silica particles with an average particle diameter of 75 nm that have been surface-treated with a silane coupling agent having a methacryloyl group. The "Amount of Hollow Silica Particles, Particle Diameter 65 nm" column of the "First Layer" in Table 1 shows the amount of hollow silica particles with an average particle diameter of 65 nm that have been surface-treated with a silane coupling agent having a methacryloyl group. The column "Amount of porous particles" in "First layer" in Table 1 indicates the amount of porous particles having an average particle size of 6 μm (manufactured by Sekisui Plastics Co., Ltd., trade name "Techpolymer SBX-6"). The column "Amount of solid silica particles having a particle size of 12 nm" in "First layer" in Table 1 indicates the amount of solid silica particles having an average particle size of 12 nm (manufactured by Nissan Chemical Industries, Ltd., trade name "MIBK-AC-2140Z"). The column "Amount of PETA" in "Binder resin component" in "First layer" in Table 1 indicates the amount of pentaerythritol triacrylate (PETA) incorporated as a binder resin component. The column "Amount of fluorine atom-containing polyfunctional (meth)acrylate oligomer" in the "Binder resin component" of the "First layer" in Table 1 indicates the amount of fluorine atom-containing polyfunctional (meth)acrylate oligomer (polyfunctional (meth)acrylate oligomer having a perfluoropolyether group, manufactured by Shin-Etsu Chemical Co., Ltd., trade name "X-71-1203M") blended as a binder resin component. The column "Amount of leveling agent" in the "First layer" in Table 1 indicates the amount of a leveling agent (manufactured by Dainichiseika Color & Chemicals Mfg. Co., Ltd., trade name "Seikabeam 1028 (MB)"). The column "Amount of MEK" in the "Solvent" of the "First layer" in Table 1 indicates the amount of methyl ethyl ketone (MEK) blended as a solvent. The column "MIBK content" in "Solvent" of "First Layer" in Table 1 indicates the content of methyl isobutyl ketone (MIBK) added as a solvent.The "PGME content" column in the "Solvent" section of the "First Layer" in Table 1 indicates the content of propylene glycol monomethyl ether acetate (PGME) used as a solvent. The "Refractive Index" column in the "Second Layer" in Table 1 indicates the calculated theoretical refractive index of the second layer.
[0188]
[0189] The results in Table 1 demonstrate that the optical laminates of the Examples can suppress odor generation while improving environmental friendliness. In particular, in the optical laminates of Examples 5 to 8, 13, and 14, the adsorbent particles contained particles of different particle sizes. In particular, in the optical laminates of Examples 5 to 8 and 13, the ratio of the mass of adsorbent particles having a particle size of 90.0 nm or more to the total mass of adsorbent particles contained in the first layer was 30% or more and 80% or less. It was found that the sensory evaluation results for odor, particularly for the optical laminates of Examples 5 to 8, 13, and 14, were "AA" or "A." Furthermore, it was found that in the optical laminates of Examples 5 to 8, 13, and 14, the value obtained by subtracting the theoretical refractive index of the first layer from the theoretical refractive index of the second layer was 0.24 or more, and the luminous reflectance Y value was 0.34% or less. Furthermore, it was found that the sensory evaluation of odor for the optical laminate of Example 5 was rated "AA," while the sensory evaluation of odor for the optical laminate of Example 13 was rated "A." In Example 5, 100 parts by mass of PETA was blended as the binder resin component of the first layer, and no polyfunctional (meth)acrylate oligomer containing fluorine atoms was blended. In Example 13, 30 parts by mass of PETA and 70 parts by mass of polyfunctional (meth)acrylate oligomer containing fluorine atoms were blended as the binder resin components of the first layer. Examples 5 and 13 were similar except for the binder resin components of the first layer. The sensory evaluation of odor for Example 5 was rated "AA" and for Example 13 was rated "A." This indicates that the binder resin not containing fluorine allows the first layer to more effectively adsorb odor components. Furthermore, in Example 14, in which 100 parts by mass of PETA was blended as the binder resin component of the first layer and no fluorine atom-containing polyfunctional (meth)acrylate oligomer was blended, the result of the odor sensory evaluation was also "AA." This also shows that the absence of fluorine in the binder resin allows the first layer to more effectively adsorb odor components.
[0190] It is also possible to combine the multiple components disclosed in the above embodiments as needed, or to delete some of the components disclosed in the above embodiments.
[0191] REFERENCE SIGNS LIST 1 Optical laminate 10 Resin substrate 20 First layer 21 Adsorptive particles 22 Binder resin 23 Solid particles 30 Second layer 31 Hard coat layer 40 Display element
Claims
1. An optical laminate comprising a resin substrate and a first layer, wherein the resin substrate contains a resin derived from a biomass material as a main component, the first layer contains adsorbent particles, the adsorbent particles being at least one type of particle selected from hollow particles and porous particles, and the optical laminate has a total light transmittance of 70% or more and a haze of 2.0% or less.
2. The optical laminate according to claim 1, wherein the adsorbent particles are light-transmitting particles.
3. The optical laminate according to claim 1, wherein the adsorbent particles comprise silica or alumina.
4. The optical laminate of claim 1, wherein the adsorbent particles comprise hollow silica particles.
5. The optical laminate according to claim 1, wherein the average distance between the centers of gravity of the adsorptive particles in the first layer is defined as average La, and the average La is 90 nm or more and 130 nm or less.
6. The optical laminate according to claim 1, wherein the average distance between the centers of gravity of the adsorbent particles in the first layer is defined as average La, the standard deviation of the distance between the centers of gravity of the adsorbent particles is defined as standard deviation Lσ, and the value Lσ / La obtained by dividing the standard deviation Lσ by the average La is 0.11 or more and 0.30 or less.
7. The optical laminate according to claim 1, wherein the adsorptive particles have an average particle size of 60.0 nm or more and 140.0 nm or less.
8. The optical stack of claim 1, wherein the first layer further contains solid particles.
9. The optical laminate according to claim 1, wherein the resin derived from a biomass material contained in the resin substrate is a polyester derived from a biomass material.
10. The optical laminate according to claim 1, wherein the first layer further contains a binder resin.
11. The optical laminate according to claim 10, wherein the content of the adsorbent particles is 15 parts by mass or more and 180 parts by mass or less per 100 parts by mass of the binder resin.
12. The optical laminate according to claim 1, further comprising a second layer between the resin substrate and the first layer, the second layer containing a resin derived from a biomass material.
13. The optical laminate according to claim 12, wherein the resin derived from a biomass material is a (meth)acrylic resin derived from a biomass material.
14. The optical laminate according to claim 12, wherein the second layer is a hard coat layer.
15. A polarizing plate comprising: a polarizer having a polarizer first surface and a polarizer second surface; a first transparent protective plate arranged on the polarizer first surface side of the polarizer; and a second transparent protective plate arranged on the polarizer second surface side of the polarizer, wherein at least one of the first transparent protective plate and the second transparent protective plate is an optical laminate described in any one of claims 1 to 14, and the optical laminate is arranged so that the surface on the first layer side faces away from the polarizer.
16. A face panel for an image display device, comprising: a plate-like member which is a resin plate or a glass plate; and an optical laminate according to any one of claims 1 to 14, arranged on the plate-like member, wherein the optical laminate is arranged so that the surface on the first layer side faces away from the plate-like member.
17. An image display device comprising: a display element; and an optical laminate according to any one of claims 1 to 14, disposed on the display element.