Method for producing optical member and use of ultraviolet ray cured resin composition for same

Patent metadata

Field	Value
Publication number	US-10179445-B2
Application number	US-201514674278-A
Country	US
Kind code	B2
Filing date	Mar 31, 2015
Priority date	Oct 21, 2011
Publication date	Jan 15, 2019
Grant date	Jan 15, 2019

Abstract

Method for producing an optical member, in which at least two optical substrates, of which at least either has a light shielding portion, are bonded to each other using an ultraviolet ray cured resin composition containing (A) a (meth)acrylate and (B) a photopolymerization initiator, an optical member obtained by the producing method, the use of an ultraviolet ray cured resin composition containing (A) a (meth)acrylate and (B) a photopolymerization initiator, and the ultraviolet ray cured resin composition. A bonded optical member causing little damage to an optical substrate, and exhibiting favorable productivity and excellent cure extent and adherence, for example, a touch panel or a display body unit having an optical substrate having a light shielding portion can be produced by the producing method of the present invention, and an optical member exhibiting high cure extent of resin at a light shielding portion and high reliability can be obtained.

First claim

The invention claimed is:

1. A method for producing an optical member including at least an optical substrate having a light shielding portion and at least a second optical substrate to be bonded to said optical substrate having a light shielding portion, the method comprising the following Processes 1 to 3:
Process 1: coating said optical substrate having a light shielding portion with an ultraviolet ray cured resin composition consisting of (A) a (meth)acrylate, (B) a photo-radical polymerization initiator, and a softening component, to form a coating layer having an optical substrate side and a side opposite said optical substrate side, said side opposite said optical substrate side being exposed to atmosphere and defining an atmosphere side, and irradiating the coating with ultraviolet rays from said atmosphere side, in air, to form a cured product layer having a cured part present on the optical substrate side facing the light shielding portion of the optical substrate and an uncured part present on said side opposite said optical substrate side, the cured part being cured by irradiating, with ultraviolet rays from the atmosphere side, in air, the ultraviolet ray cured resin composition on the light shielding portion of the optical substrate, the uncured part being composed of the ultraviolet ray cured resin composition;
Process 2: a process of bonding said second optical substrate to the uncured part of the cured product layer of the optical substrate having the light shielding portion obtained in Process 1 to form a bonded optical substrate; and
Process 3: a process of curing the cured product layer by irradiating the cured product layer having the uncured part in the bonded optical substrate with ultraviolet rays through the bonded optical substrate having the light shielding portion.

2. The method for producing an optical member according to claim 1 , wherein the ultraviolet ray cured resin composition includes, as the (meth)acrylate (A), both of
(i) at least either an urethane(meth)acrylate or a (meth)acrylate having a polyisoprene backbone, and
(ii) a (meth)acrylate monomer.

3. The method for producing an optical member according to claim 2 , wherein the ultraviolet ray cured resin composition includes, as the (meth)acrylate (A),
a urethane(meth)acrylate which is obtained by reacting a polyhydric alcohol in which a polyester polyol is excluded, a polyisocyanate, and a hydroxyl group-containing (meth)acrylate, and a weight average molecular weight of the urethane(meth)acrylate is from 7,000 to 25,000.

4. The method for producing an optical member according to claim 1 , wherein the ultraviolet ray cured resin composition includes, as the (meth)acrylate (A), both of
(i) an urethane(meth)acrylate obtained by a reaction of poly C2-C4 alkylene gycol, diisocyanate, and hydroxy C2-C4 alkyl(meth)acrylate, and
(ii) a (meth)acrylate monomer.

5. The method for producing an optical member according to claim 1 , wherein an acylphosphine oxide compound is included as the photo-radical polymerization initiator (B).

6. The method for producing an optical member according to claim 5 , wherein the acylphosphine oxide compound is at least a compound selected from the group consisting of 2,4,6-trimethylbenzoyldiphenylphosphine oxide, 2,4,6-trimethylbenzoylphenylethoxyphosphine oxide, bis(2,4,6-trimethyl benzoyl)-phenylphosphine oxide, and bis(2,6-dimethoxybenzoyl)-2,4,4-trimethyl-pentylphosphine oxide.

7. The method for producing an optical member according to claim 1 , wherein the ultraviolet ray cured resin composition consists of (A) at least a (meth)acrylate selected from the group consisting of an urethane(meth)acrylate, a (meth)acrylate having a polyisoprene backbone, and a (meth)acrylate monomer, (B) a photo-radical polymerization initiator, and a softening component.

8. The method for producing an optical member according to claim 1 , wherein the ultraviolet ray cured resin composition includes, as the (meth)acrylate (A),
(ii) a (meth)acrylate monomer which is at least one kind of a (meth)acrylate having a cyclic backbone selected from the group consisting of acryloylmorpholine, dicyclopentenyl acrylate and dicyclopentanyl (meth)acrylate, in the weight proportion of 10% by weight or more of the ultraviolet ray cured resin composition.

9. The method for producing an optical member according to claim 1 , wherein the softening component is
at least one kind of a compound selected from the group consisting of a compound having a structure represented by Formula (1), an ester of phosphoric acid, a glycol ester, an ester of citric acid, an ester of aliphatic dibasic acid, an ester of fatty acid, an epoxy plasticizer, and a hydrogenated terpene resin:
R 1 OC 2 H 4 n OC 3 H 6 m OR 2   (1)

wherein in Formula (1), n represents an integer from 0 to 40; m represents an integer from 10 to 50; and R 1 and R 2 are the same as or different from each other, and R 1 and R 2 are an alkyl group having from 1 to 18 carbon atoms, an alkenyl group having from 1 to 18 carbon atoms, an alkynyl group having from 1 to 18 carbon atoms, or an aryl group having from 5 to 18 carbon atoms.

10. The method for producing an optical member according to claim 1 , wherein the ultraviolet ray cured resin composition includes, as the (meth)acrylate (A), acryloylmorpholine or dicyclopentenyl acrylate.

11. The method for producing an optical member according to claim 1 , wherein the ultraviolet ray cured resin composition includes, as the (meth)acrylate (A), both of:
(1) a (meth)acrylate having a cyclic backbone, and
(2) an alkyl (meth)acrylate having from 10 to 20 carbon atoms or an alkyl (meth)acrylate having from 1 to 5 carbon atoms and a hydroxyl group.

12. The method for producing an optical member according to claim 1 , wherein said second optical substrate comprises an uncured part of a cured product layer of an optical substrate obtained by Process 1.

Assignees

• Nippon Kayaku Kk

Inventors

• Kobayashi Daisuke
• Motohashi Hayato
• Matsuo Yuichiro

Classifications

• C09J2203/318

  for the production of liquid crystal displays · CPC title

• Y10T428/31938

  Polymer of monoethylenically unsaturated hydrocarbon · CPC title

• B32B2309/68

  Vacuum · CPC title

• C09J5/00

  Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers · CPC title

• B32B2255/26

  Polymeric coating · CPC title