Method for forming anti-glare hard coat layer
An object of the present invention is to provide a method for forming an antiglare hard coat layer having a concavo-convex shape that exhibits a good antiglare property and being superior in scratch resistance.
1. A method for forming an antiglare hard coat layer having a concavo-convex shape on a surface, on at least one surface of a transparent support substrate, comprising:
a mold substrate production step of producing a mold substrate having a concavo-convex shape on a surface thereof;
an application step of applying a hard coating composition to one surface of the transparent support substrate, thereby forming an uncured hard coat layer;
a surface contact step of bringing both the substrates into surface contact with each other in a direction in which the concavo-convex shape surface of the mold substrate and a surface of the uncured hard coat layer face each other;
a curing step of applying active energy rays, thereby curing the uncured hard coat layer; and
a peeling step of peeling the mold substrate from the cured hard coat layer,
wherein
the hard coating composition contains a polymerizable unsaturated group-containing oligomer or polymer having a weight-average molecular weight in a range of 1000 to 200000,
a peel strength of a surface contact part of the concavo-convex shape surface of the mold substrate and the uncured hard coat layer surface is in a range of 0.01 to 2 N/25 mm,
a peel strength of the surface contact part of the concavo-convex shape surface of the mold substrate and the hard coat layer after the application of the active energy rays is in a range of 0.005 to 1.5 N/25 mm,
a pressing pressure in the surface contact step of the concavo-convex shape surface of the mold substrate and the uncured hard coat layer surface is 0.001 to 5 MPa, and
a concavo-convex shape transfer rate achieved when the pressing pressure is in the above range is 75 to 100%.
2. The method for forming an antiglare hard coat layer according to claim 1 , wherein
the concavo-convex shape of the surface of the mold substrate is a concavo-convex shape formed by applying a concavo-convex shape-forming coating composition containing a first component and a second component, and then phase-separating the first component and the second component.
3. The method for forming an antiglare hard coat layer according to claim 1 , wherein
the hard coating composition contains
the polymerizable unsaturated group-containing oligomer or polymer having the weight-average molecular weight in the range of 1000 to 200000, and
a polymerizable unsaturated group-containing monomer having a polymerizable unsaturated group equivalent of 90 to 500 g/eq,
wherein an amount of the polymerizable unsaturated group-containing oligomer or polymer is 15 to 85 parts by mass per 100 parts by mass of a solid content of a layer-forming resin component contained in the hard coating composition, and an amount of the polymerizable unsaturated group-containing monomer is 85 to 15 parts by mass.
4. The method for forming an antiglare hard coat layer according to claim 1 , wherein the polymerizable unsaturated group contained in the polymerizable unsaturated group-containing polymer is one or more selected from the group consisting of an acryloyl group and a methacryloyl group.
5. The method for forming an antiglare hard coat layer according to claim 1 , wherein a hardness of the antiglare hard coat layer is a pencil hardness of 2H or higher.
6. The method for forming an antiglare hard coat layer according to claim 1 , wherein
the antiglare hard coat layer having the concavo-convex shape on the surface thereof has a surface concavo-convex shape having
a ten-point average roughness Rz JIS of 0.2 to 1.0 μm, and
an average length RSm of a roughness curve element of 5 to 100 μm.
7. The method for forming an antiglare hard coat layer according to claim 1 , wherein
the hard coating composition further contains light transmissive fine particles having an average particle diameter of 0.5 to 10 μm, and
a refractive index (Rf1) of the light transmissive fine particles and a refractive index (Rf2) of a layer-forming resin component contained in the hard coating composition satisfy a relationship:
0.01≤≤| Rf 1− Rf 2|≤0.23.
8. The method for forming an antiglare hard coat layer according to claim 1 , wherein
the antiglare hard coat layer having the concavo-convex shape on the surface thereof has a surface concavo-convex shape having
a sum total value (%) of transmitted image definitions (%) for optical combs with five widths of 0.125 mm, 0.25 mm, 0.5 mm, 1.0 mm and 2.0 mm is in a range of 300 to 480.
9. The method for forming an antiglare hard coat layer according to claim 1 , further comprising, after the peeling step,
a step of forming one or more functional layers selected from the group consisting of a high refractive index layer, a low refractive index layer and an antifouling layer on the concavo-convex shape surface of the obtained antiglare hard coat layer.
10. The method for forming an antiglare hard coat layer according to claim 1 , further comprising
a decorative layer forming step of forming a decorative layer on the other surface of the transparent support substrate.
11. A method for producing a display having an antiglare hard coat layer, comprising
conducting the method of claim 1 to produce the antiglare hard coat layer, and
a step of placing the antiglare hard coat layer on a surface of the display.
12. The method for producing a display having an antiglare hard coat layer according to claim 11 , wherein the display is a touch panel display.