Optical film, method for producing optical film, and surface light-emitting body

Patent metadata

Field	Value
Publication number	US-2016123552-A1
Application number	US-201414891710-A
Country	US
Kind code	A1
Filing date	May 20, 2014
Priority date	May 23, 2013
Publication date	May 5, 2016
Grant date	—

Abstract

This optical film includes a substrate and a plurality of convex microlenses arrayed on the substrate. The microlenses have an α-region and a β-region. The β-region occupies the outer portion of the convex shape of the microlenses, and is positioned in a manner so as to cover the α-region. In an adhesion test conforming to ISO 2409 for measuring the adhesiveness of the substrate and the optical film, the test result is class 0 or class 1.

First claim

1 . An optical film comprising a base material and a plurality of convex microlenses arranged on the base material, the microlens having an α-region and a β-region, the β-region occupying the outer portion of the convex shape of the microlens and being positioned so as to cover the α-region, wherein
a resin composition constituting the α-region has a test result of class 0 or class 1 in an adhesion test in conformity with ISO 2409 for measuring adhesiveness between the base material and the resin composition constituting the α-region.

2 . The optical film according to claim 1 , wherein the resin composition constituting the α-region includes at least one unit selected from the group consisting of a monomer unit having a bisphenol skeleton and a polyfunctional urethane (meth)acrylate unit.

3 . The optical film according to claim 1 , further comprising a primer layer including a urethane resin between the base material and the microlens.

4 . An optical film comprising a plurality of convex microlenses arranged therein, the microlens having an α-region and a β-region, the β-region occupying the outer portion of the convex shape of the microlens and being positioned so as to cover the α-region, wherein
an average value of curls at four corners when the 50 mm-square optical film is dried at 60° C. for 4 hours is 1.0 mm or less.

5 . The optical film according to claim 4 , wherein a resin composition constituting the α-region includes at least one unit selected from the group consisting of a polyoxyalkylene glycol di(meth)acrylate unit, a polyester polyol di(meth)acrylate unit, and an aromatic ester diol di(meth)acrylate unit.

6 . The optical film according to claim 5 , wherein the total content ratio of the polyoxyalkylene glycol di(meth)acrylate unit, the polyester polyol di(meth)acrylate unit, and the aromatic ester diol di(meth)acrylate unit to the total mass of the resin composition constituting the α-region is 10% by mass or more.

7 . An optical film comprising a plurality of convex microlenses arranged therein, the microlens having an α-region and a β-region, the β-region occupying the outer portion of the convex shape of the microlens and being positioned so as to cover the α-region, wherein
a difference in light extraction efficiency of a surface light-emitting body before and after a rubbing test of reciprocating a waste cloth 1000 times with a weight of 200 g on the β-region of the optical film is −0.01% to 0.01%.

8 . The optical film according to claim 7 , wherein a resin composition constituting the β-region includes a trifunctional or higher polyfunctional (meth)acrylate unit.

9 . The optical film according to claim 8 , wherein the trifunctional or higher polyfunctional (meth)acrylate unit is at least one trifunctional or higher polyfunctional (meth)acrylate unit selected from the group consisting of pentaerythritol tri(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and tris(2-(meth)acryloyloxyethyl)isocyanurate.

10 . The optical film according to claim 8 , wherein a content ratio of the trifunctional or higher polyfunctional (meth)acrylate unit to the total mass of the resin composition constituting the β-region is 30% by mass or more.

11 . An optical film comprising a plurality of convex microlenses arranged therein, the microlens having an α-region and a β-region, the β-region occupying the outer portion of the convex shape of the microlens and being positioned so as to cover the α-region, wherein
a surface resistance value of the β-region in a resistivity test in conformity with IEC 60093 is 10 13 Ω/cm 2 or less.

12 . The optical film according to claim 11 , wherein a resin composition constituting the β-region includes at least one material selected from the group consisting of an ionic liquid, a quaternary ammonium compound, an ionic surfactant, and a conductive polymer.

13 . The optical film according to claim 12 , wherein the resin composition constituting the β-region includes an ionic liquid.

14 . A method for producing the optical film according to claim 1 , the method comprising:
while a roll mold having an outer peripheral surface on which a plurality of concave microlens transferring portions are arranged is rotated and a base material is allowed to travel in a rotational direction of the roll mold along the outer peripheral surface of the roll mold, coating the outer peripheral surface of the roll mold with an active energy ray curable composition B to fill a part of the concave shapes of the microlens transferring portions with the active energy ray curable composition B; supplying an active energy ray curable composition A to a space between the outer peripheral surface of the roll mold and the base material; irradiating a region between the outer peripheral surface of the roll mold and the base material with an active energy ray in a state where at least the active energy ray curable composition A is interposed between the outer peripheral surface of the roll mold and the base material to obtain cured products of the active energy ray curable composition A and the active energy ray curable composition B; and releasing the cured products from the roll mold.

15 . The method for producing the optical film according to claim 14 , wherein the application of the active energy ray curable composition B in the filling with the active energy ray curable composition B is coating for making the active energy ray curable composition B follow a surface of the concave microlens transferring portion on the outer peripheral surface of the roll mold.

16 . The method for producing the optical film according to claim 14 , further comprising irradiating the active energy ray curable composition B with an active energy ray to cure the active energy ray curable composition B between the filling with the active energy ray curable composition B and the supplying of the active energy ray curable composition A.

17 . The method for producing the optical film according to claim 14 , wherein a viscosity of the active energy ray curable composition B is lower than a viscosity of the active energy ray curable composition A.

18 . A surface light-emitting body comprising the optical film according to claim 1 .

Assignees

• Mitsubishi Rayon Co

Inventors

• Okuno Daichi
• Toda Masatoshi

Classifications

• F21V5/004 Primary

  using microlenses · CPC title

• B29D11/00365

  Production of microlenses (lenticular sheets B29D11/00278) · CPC title

• C08F222/1067

  of alcohol terminated epoxy functional polymers, e.g. epoxy(meth)acrylates · CPC title

• G02B3/005

  arranged along a single direction only, e.g. lenticular sheets (G02B3/0043 takes precedence) · CPC title

• B32B2307/21

  Anti-static · CPC title