Method for producing antireflection film, antireflection film, and coating composition

Patent metadata

Field	Value
Publication number	US-2016187540-A2
Application number	US-201213451214-A
Country	US
Kind code	A2
Filing date	Apr 19, 2012
Priority date	Apr 22, 2011
Publication date	Jun 30, 2016
Grant date	—

Abstract

The method for producing an antireflection film is provided. The method includes, a step of coating a coating composition including the following components (A) to (D) on a base material to form a coating film, a step of volatilizing the solvent from the coating film for drying the coating film, and a step of curing the coating film to form a cured layer, in which a multilayer structure having different refractive indices from the coating composition is formed: (A) a fluorine-containing polymer with a specific structure, having a polyalkylene oxide group in the molecule, (B) non-surface-modified inorganic fine particles, or inorganic fine particles that are surface-treated with a silane coupling agent having a molecular weight of 600 or less, (C) a curable binder having no fluorine atom in the molecule, and (D) a solvent, provided that the mass ratio of [component (A)+component (B)]/[component (C)] is from 1/199 to 60/40.

First claim

What is claimed is:

1 . A method for producing an antireflection film, comprising, in this order:
a step of preparing a coating composition formed by mixing the following components (A) to (D); a step of coating the coating composition on a base material to form a coating film; a step of volatilizing the solvent from the coating film for drying the coating film; and a step of curing the coating film to form a cured layer, wherein a multilayer structure having different refractive indices from the coating composition is formed: (A) a fluorine-containing polymer having a polyalkylene oxide group in the molecule, represented by the following general formula (1); (B) non-surface-modified inorganic fine particles, or inorganic fine particles that are surface-treated with a silane coupling agent having a molecular weight of 600 or less; (C) a curable binder having no fluorine atom in the molecule; and (D) a solvent, provided that the mass ratio of [component (A)+component (B)]/[component (C)] is from 1/199 to 60/40.
(MF1)a-(MF2)b-(MF3)c-(MA)d-(MB)e-(MC)f-(MD)g   General Formula (1):

(in the general formula (1), a to f each represent the molar fraction of each constituent unit, and g represents % by mass in the fluorine-containing polymer, representing values satisfying the relationships of 0≦a≦70, 0≦b≦70, 0≦c≦80, 30≦a+b+c≦90, 0≦d≦50, 0≦e≦50, 0.1≦f≦50, and0≦g≦15, respectively; (MF1) represents a constituent unit that is polymerized from a monomer represented by CF 2 ═CF—Rf 1 . Rf 1 represents a perfluoroalkyl group having 1 to 5 carbon atoms; (MF2) represents a constituent unit that is polymerized from a monomer represented by CF 2 ═CF—ORf 12 . Rf 12 represents a fluorine-containing alkyl group having 1 to 30 carbon atoms; (MF3) represents a constituent unit that is polymerized from a monomer represented by CH 2 ═CRo-L-Rf 13 . R o represents a hydrogen atom, a halogen atom, or a methyl group, L represents a divalent linking group, and Rf 13 represents a fluorine-containing alkyl group having 1 to 20 carbon atoms; (MA) represents a constituent unit having at least one of a group having an unsaturated double bond and a ring-opening polymerization reactive group; (MB) represents a non-crosslinkable constituent unit; (MC) represents a constituent unit that is polymerized from a monomer having at least one polyalkylene oxide group of the following general formula (2):

(in the general formula (2), R o represents a hydrogen atom, a halogen atom, or a methyl group, L represents a divalent linking group, R e represents a hydrogen atom or an alkyl group having 1 to 10 carbon atoms, m represents an integer of 2 to 50, and n represents an integer of 1 to 5. Further, when m is 2 or more, a plurality of —(C n H 2n —O)— may be repeating units that are different from each other); and
(MD) represents a constituent unit having at least one polysiloxane structure.

2 . The method for producing an antireflection film according to claim 1 , wherein the component (B) is an inorganic fine particles that are surface-treated with a silane coupling agent and the silane coupling agent has a molecular weight of 90 to 600.

3 . The method for producing an antireflection film according to claim 1 , wherein the inorganic fine particles of the component (B) are metal oxide fine particles having a metal oxide with silicon as a constituent at least on the surface of particles.

4 . The method for producing an antireflection film according to claim 3 , wherein the component (B) is inorganic fine particles surface-treated with a silane coupling agent and the surface modification rate a thereof is from 0.1% to 9%.

5 . The method for producing an antireflection film according to claim 1 , wherein L in the general formula (2) is a divalent linking group having 1 to 9 carbon atoms.

6 . The method for producing an antireflection film according to claim 1 , wherein the component (A) contains a polymerizable functional group in the molecule.

7 . The method for producing an antireflection film according to claim 1 , wherein the inorganic fine particles of the component (B) are metal oxide fine particles having an average particle diameter of 1 to 150 nm and a refractive index of 1.46 or less.

8 . The method for producing an antireflection film according to claim 1 , wherein the curable binder of the component (C) contains a compound having at least a plurality of unsaturated double bonds in the molecule.

9 . The method for producing an antireflection film according to claim 1 , wherein the coating composition further comprises a curable compound having a fluorine atom in the molecule as a component (E).

10 . The method for producing an antireflection film according to claim 9 , wherein the component (A) and the component (E) are both fluorine-containing copolymers and each of the copolymers has at least two kinds of common constituent units that form a copolymer.

11 . The method for producing an antireflection film according to claim 1 , wherein the free energy of mixing (ΔG=ΔH−T·ΔS) of the curable binder of the component (C) and the fluorine-containing polymer of the component (A) is more than zero.

12 . The method for producing an antireflection film according to claim 9 , wherein the mass ratio of [component (A)+component (B)+component (E)]/[component (C)] in the coating composition is from 1/199 to 60/40.

13 . The method for producing an antireflection film according to claim 1 , wherein the solvent of the component (D) contains a volatile solvent having a boiling point of higher than 100° C.

14 . An antireflection film obtained by the production method according to claim 1 .

15 . The antireflection film according to claim 14 , wherein the film thickness of the cured layer formed from the coating composition is from 0.1 to 20 p.m, the cured layer includes a low refractive index layer comprising the component (B) which is distributed unevenly in the air-interface side of the cured layer, and the film thickness of the low refractive index layer is from 40 to 300 nm.

16 . The antireflection film according to claim 14 , wherein the film thickness of the cured layer formed from the coating composition is from 0.6 to 20 pm.

17 . The antireflection film according to claim 15 , wherein the refractive index of the low refractive index layer in which the component (B) is distributed unevenly in the air-interface side is from 1.25 to 1.48.

18 . A coating composition formed by mixing the following components (A) to (D):
(A) a fluorine-containing polymer having a polyalkylene oxide group in the molecule, represented by the following general formula (1); (B) non-surface-modified inorganic fine particles, or inorganic fine particles that are surface-treated with a silane coupling agent having a molecular weight of 600 or less; (C) a curable binder having no fluorine atom in the molecule; and (D) a solvent, provided that the mass ratio of [component (A)+component (B)]/[component (C)] is from 1/199 to 60/40.
(MF1)a-(MF2)b-(MF3)c-(MA)d-(MB)e-(MC)f-(MD)g   General Formula (1):

(in the general formula (1), a to f each represent the molar fraction of each constituent unit, and g represents % by mass in the fluorine-containing polymer, representing values satisfying the relationships of 0≦a≦g70, 0≦b≦70, 0≦c≦80, 30≦a+b+c≦90, 0≦d≦50, 0≦e≦50, 0.1≦f≦50, and 0≦g≦15, respectively; (MF1) represents a constituent unit that is polymerized from a

Assignees

• Akutagawa Nobuyuki
• Yoneyama Hiroyuki
• Wakizaka Daiki
• Fujifilm Corp

Inventors

• Akutagawa Nobuyuki
• Yoneyama Hiroyuki
• Wakizaka Daiki

Classifications

• G02B1/111 Primary

  using layers comprising organic materials · CPC title

• B05D5/061

  Special surface effect · CPC title

• Y10T428/24975

  No layer or component greater than 5 mils thick · CPC title

• Y10T428/3154

  Of fluorinated addition polymer from unsaturated monomers · CPC title

• C08K9/04

  Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)} · CPC title