JP2010076423A - Resin laminated body and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a resin laminated body that is hardly warped and has excellent adhesiveness and abrasion resistance. <P>SOLUTION: The method for manufacturing the resin laminated body includes: a first step wherein, to form a coating layer, a solventless activation energy line hardening mixture is applied to the adhesion layer of a transfer film formed by sequentially forming a release layer, an antireflective layer, a first cured coating layer, and the adhesion layer on one face of a transparent film; a second step wherein the coating layer side is applied to a resin base material; a third step wherein the activation energy line hardening mixture in the coating layer is hardened to form a second cured coating layer; and a fourth step wherein the transparent film is peeled off, leaving the second cured coating layer, the adhesion layer, the first cured coating layer, and the antireflective layer stacked on the resin base material. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a resin laminate having a plate-like shape excellent in transparency, antireflection performance, and scratch resistance, and a method for producing the same, which are suitable for applications such as a front plate of a display.

  Transparent resins such as acrylic resins and polycarbonate resins are widely used as industrial materials, building materials, and the like. Particularly in recent years, it has been used as a front plate for various displays such as CRTs, liquid crystal televisions and plasma displays because of its transparency and impact resistance.

  In recent years, an anti-reflection function has been cited as one of the important performance requirements for a front panel, and the anti-reflection function reduces reflected light from indoor fluorescent lamps and the like reflected on the front panel, and displays images. This is a function for clearer display. As one of the principles of the antireflection function, the light reflected by the high refractive index layer and the low refractive index layer are formed by forming an antireflection film having a structure having a low refractive index layer on the surface of the high refractive index layer. It is possible to reduce the reflected light by using the optical path difference between the light reflected by the light and causing the light to interfere with each other.

  A conventional antireflection film having such an antireflection function is usually formed by sequentially laminating a high refractive index layer and a low refractive index layer on a plastic substrate by a dip method. Therefore, the production efficiency is low, which has been a cause of cost increase when producing an antireflection film. Further, when the dip method is adopted, the film thickness is likely to be uneven depending on the speed at which the plastic substrate is pulled up from the dip solution, and it is usually difficult to obtain a uniform nano-order film.

  Therefore, as a method for continuously forming a functional layer such as a uniform nano-order antireflection film, the antireflection layer (transfer layer) formed on the release material is thermally transferred or pressure-sensitive transferred to the surface of the transfer target. A method is disclosed (see Patent Document 1). However, a large-scale heating facility is required, and it takes time to heat, resulting in a problem that the production speed cannot be increased. Furthermore, there is a problem that air bubbles are likely to be caught between the base material and the antireflection layer (transfer layer), and surface irregularities due to foreign matter are likely to occur.

  On the other hand, after the antireflection layer is bonded to the transfer surface via an ultraviolet curable adhesive layer and the adhesive layer is solidified by irradiating with ultraviolet rays (UV), the base film on which the antireflection layer is formed is formed. A method of peeling and transferring the antireflection layer to a transfer surface (hereinafter referred to as “UV lamination transfer method”) is disclosed (see Patent Document 2). Although this method can perform transfer with relatively simple equipment and high productivity, it has been necessary to volatilize the solvent when forming the adhesive layer. In addition, since the viscosity of the adhesive used for the adhesive layer is very high, there is a problem that air bubbles are easily bitten and surface irregularities due to foreign matter are likely to occur. Furthermore, since the hard coat function and the adhesive function are carried by a single layer, there is a tendency that the adhesion to the substrate is insufficient. In addition, since the adhesive layer has a tack, it is necessary to affix the separator film in order to store the transfer film in a roll shape, and the process is complicated for continuous production.

  Also disclosed is a UV lamination transfer method in which an ultraviolet curable coating is applied to a substrate in advance, and an antireflection layer (transfer layer) is transferred to the surface of the transfer medium by ultraviolet irradiation (see Patent Document 3). In this method, since an ultraviolet curable coating material is applied to the base material in advance, when an acrylic resin or a polycarbonate resin having poor solvent resistance is used as the base material, optical distortion due to non-uniform dissolution is caused. In addition, detailed manufacturing conditions such as temperature and a method of coating when forming the coating layer are not described.

  In addition, a method is disclosed in which an ultraviolet curable coating material is previously applied on an antireflection layer (transfer layer), and then the antireflection layer is transferred to the substrate by being bonded to the substrate and irradiated with ultraviolet rays (Patent Document). 4). This method has a problem in that since the ultraviolet curable coating is directly applied to the antireflection layer, the adhesion of the obtained laminate is difficult to obtain, and the productivity cannot be increased. In addition, there is no specific disclosure of a method of applying an ultraviolet curable mixture in forming the coating layer.

  Further, a method is disclosed in which an antireflection layer, a protective layer, and an adhesive layer are formed in advance on a film and transferred to a base material (see Patent Document 5). This method is a laminated structure advantageous for increasing the hardness because the antireflection layer and the protective layer are in contact with each other. However, in order to achieve the increased hardness, it is necessary to increase the thickness of the protective layer. It was greatly deformed (warped) and it was difficult to obtain a smooth surface.

  In particular, in the antireflection laminate, it is necessary to propose a production method and a laminate that are more prominent in optical distortion and that are more excellent in appearance.

JP 2006-45355 A JP 2003-215308 A Japanese Patent Laid-Open No. 7-151905 JP 2006-212987 A JP 2005-96078 A

  An object of the present invention relates to a resin laminate having a plate shape or the like excellent in transparency, antireflection performance, adhesion, scratch resistance, productivity, and appearance, and a method for producing the same.

  The present invention is a solventless active energy ray curing on the adhesive layer of a transfer film in which a release layer, an antireflection layer, a first cured coating layer, and an adhesive layer are sequentially formed on one side of a transparent film. A first step of applying an adhesive mixture to form a coating layer, a second step of sticking the coating layer side to a resin substrate, and a second curing by curing the active energy ray-curable mixture in the coating layer A third step of forming a coating layer, and the second cured coating layer laminated on the resin substrate, the adhesive layer, the first cured coating layer, and the antireflection layer, leaving the transparent film And a fourth step of removing the resin laminate.

  It is preferable that it is the said manufacturing method whose film thickness of a 1st cured coating film layer is 0.5 micrometer-10 micrometers, and the film thickness of a 2nd cured coating film layer is 0.5 micrometer-40 micrometers.

  In the second step, the surface temperature of the resin substrate is set to 40 ° C. to 100 ° C., and the viscosity of the active energy ray-curable mixture forming the second cured coating film layer at the same temperature as the surface temperature is 15 to 120 mPa · The production method is preferably s.

  Moreover, it is preferable that it is the said manufacturing method whose antireflection layer is a structure of two or more layers.

  Furthermore, it is preferable that the antireflection layer has a single layer structure, and the refractive index of the first cured coating layer is higher than the refractive index of the antireflection layer.

  According to the present invention, it is possible to obtain a resin laminate having little warpage, excellent adhesion, and excellent scratch resistance.

  Moreover, a laminated body can be manufactured with high productivity with a simple apparatus, without volatilizing the solvent of an contact bonding layer.

  Furthermore, it is possible to provide an antireflection resin laminate having little optical distortion and few surface defects such as air bubble biting and foreign matter defects.

  The present invention is a resin laminate in which a second cured coating layer, an adhesive layer, a first cured coating layer, and an antireflection layer are sequentially laminated on at least one surface of a resin substrate surface.

  The cured coating layer improves the scratch resistance of the surface of the resin laminate, and is obtained by curing a curable mixture composed of various curable compounds that provide this scratch resistance into a film. Examples of the curable mixture used as a raw material for the first cured coating layer include a curable mixture made of a radical polymerization curable compound such as an ultraviolet curable mixture, which will be described later, and condensation polymerization such as alkoxysilane and alkylalkoxysilane. Mention may be made of curable mixtures comprising curable compounds of the system. These curable compounds are preferably cured by irradiating active energy rays such as an electron beam, radiation and ultraviolet rays, or cured by heating. These curable compounds may be used alone or in combination with a plurality of curable compounds. For convenience, the curable compound is also referred to as a “curable mixture”.

  The second cured coating film layer cures the active energy ray-curable mixture. In the present invention, the second cured coating film layer is preferably cured by ultraviolet rays from the viewpoints of productivity and physical properties. Hereinafter, the ultraviolet curable mixture will be described.

  As the ultraviolet curable mixture, it is preferable from the viewpoint of productivity to use an ultraviolet curable mixture composed of a compound having at least two (meth) acryloyloxy groups in the molecule and a photoinitiator.

  For example, the main compound having at least two (meth) acryloyloxy groups in the molecule is an esterified product obtained from 1 mol of polyhydric alcohol and 2 mol or more of (meth) acrylic acid or a derivative thereof. And esterified products obtained from polyhydric alcohols, polyhydric carboxylic acids or anhydrides thereof, and (meth) acrylic acid or derivatives thereof.

  Specific examples of esterified products obtained from 1 mol of polyhydric alcohol and 2 mol or more of (meth) acrylic acid or derivatives thereof include diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetra Di (meth) acrylate of polyethylene glycol such as ethylene glycol di (meth) acrylate; 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di ( Di (meth) acrylates of alkyl diols such as (meth) acrylate; trimethylolpropane tri (meth) acrylate, trimethylolethane tri (meth) acrylate, pentaglycerol tri (meth) acrylate, pentaerythritol tri (meth) acrylate Pentaerythritol tetra (meth) acrylate, glycerin tri (meth) acrylate, dipentaerythritol tri (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa ( Poly (meta) of a tri- or higher functional polyol such as (meth) acrylate, tripentaerythritol tetra (meth) acrylate, tripentaerythritol penta (meth) acrylate, tripentaerythritol hexa (meth) acrylate, tripentaerythritol hepta (meth) acrylate, etc. ) Acrylate;

  Furthermore, in the esterified product obtained from polyhydric alcohol, polyhydric carboxylic acid or anhydride and (meth) acrylic acid or derivative thereof, polyhydric alcohol, polyhydric carboxylic acid or anhydride and (meth) acrylic acid Preferred combinations include, for example, malonic acid / trimethylolethane / (meth) acrylic acid, malonic acid / trimethylolpropane / (meth) acrylic acid, malonic acid / glycerin / (meth) acrylic acid, malonic acid / pentaerythritol / (Meth) acrylic acid, succinic acid / trimethylolethane / (meth) acrylic acid, succinic acid / trimethylolpropane / (meth) acrylic acid, succinic acid / glycerin / (meth) acrylic acid, succinic acid / pentaerythritol / ( (Meth) acrylic acid, adipic acid / trimethylolethane / (meth) ac Auric acid, adipic acid / trimethylolpropane / (meth) acrylic acid, adipic acid / glycerin / (meth) acrylic acid, adipic acid / pentaerythritol / (meth) acrylic acid, glutaric acid / trimethylolethane / (meth) acrylic Acid, glutaric acid / trimethylolpropane / (meth) acrylic acid, glutaric acid / glycerin / (meth) acrylic acid, glutaric acid / pentaerythritol / (meth) acrylic acid, sebacic acid / trimethylolethane / (meth) acrylic acid , Sebacic acid / trimethylolpropane / (meth) acrylic acid, sebacic acid / glycerin / (meth) acrylic acid, sebacic acid / pentaerythritol / (meth) acrylic acid, fumaric acid / trimethylolethane / (meth) acrylic acid, Fumaric acid / trimethylolpropane / ( TA) acrylic acid, fumaric acid / glycerin / (meth) acrylic acid, fumaric acid / pentaerythritol / (meth) acrylic acid, itaconic acid / trimethylolethane / (meth) acrylic acid, itaconic acid / trimethylolpropane / (meta ) Acrylic acid, itaconic acid / glycerin / (meth) acrylic acid, itaconic acid / pentaerythritol / (meth) acrylic acid, maleic anhydride / trimethylolethane / (meth) acrylic acid, maleic anhydride / trimethylolpropane / ( And (meth) acrylic acid, maleic anhydride / glycerin / (meth) acrylic acid, maleic anhydride / pentaerythritol / (meth) acrylic acid, and the like.

  Other examples of compounds having at least two (meth) acryloyloxy groups in the molecule include trimethylolpropane toluylene diisocyanate, hexamethylene diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, xylene diisocyanate, 4,4'-methylenebis. 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 2-hydroxy-3 per mole of polyisocyanate obtained by trimerization of diisocyanates such as (cyclohexyl isocyanate), isophorone diisocyanate, trimethylhexamethylene diisocyanate -Methoxypropyl (meth) acrylate, N-methylol (meth) acrylamide, N-hydroxy (meth) acryl It is obtained by reacting 3 mol or more of an acrylic monomer having active hydrogen such as imide, 15,3-propanetriol-1,3-di (meth) acrylate, 3-acryloyloxy-2-hydroxypropyl (meth) acrylate, etc. Urethane (meth) acrylate; poly [(meth) acryloyloxyethylene] isocyanurate such as di (meth) acrylate or tri (meth) acrylate of tris (2-hydroxyethyl) isocyanuric acid; epoxy poly (meth) acrylate; urethane poly (Meth) acrylate; etc. are mentioned. Here, “(meth) acryl” means “methacryl” or “acryl”.

  Moreover, as an ultraviolet curable mixture which forms a 2nd cured coating film layer, a macromonomer is preferable and a urethane type macromonomer is more preferable. By using these macromonomers, the warpage of the laminate can be reduced.

  Examples of the photoinitiator include benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, acetoin, butyroin, toluoin, benzyl, benzophenone, p-methoxybenzophenone, 2,2-diethoxyacetophenone, α , Α-dimethoxy-α-phenylacetophenone, methylphenylglyoxylate, ethylphenylglyoxylate, 4,4′-bis (dimethylamino) benzophenone, 1-hydroxy-cyclohexyl-phenyl-ketone, 2-hydroxy-2- Carbonyl compounds such as methyl-1-phenylpropan-1-one; sulfur compounds such as tetramethylthiuram monosulfide and tetramethylthiuram disulfide; 2,4,6-trime Reuben benzoyl diphenyl phosphine oxide, bis (2,4,6-trimethylbenzoyl) - phenyl phosphine oxide, phosphorus compounds such as benzo dichloride ethoxy phosphine oxide; and the like.

  The addition amount of the photoinitiator is preferably 0.1% by mass or more from the viewpoint of curability by ultraviolet irradiation in 100% by mass of the ultraviolet curable mixture, and 10% by mass from the viewpoint of maintaining a good color tone of the cured coating layer. The following is preferred. Two or more photoinitiators may be used in combination.

  Various components such as a slip improver, a leveling agent, inorganic fine particles, and a light stabilizer (ultraviolet absorber, HALS, etc.) can be further added to the ultraviolet curable mixture as necessary. From the viewpoint of the transparency of the laminate, the addition amount is preferably 10% by mass or less in 100% by mass of the ultraviolet curable mixture.

  As a 1st cured coating film layer, it is preferable that a film thickness is 0.5 micrometer-10 micrometers, and it is more preferable that a film thickness is 1 micrometer-7 micrometers. In such a range, the film has sufficient surface hardness, little warpage of the film by the coating layer, and good appearance.

  As a 2nd cured coating film layer, it is preferable that a film thickness is 0.5 micrometer-40 micrometers, and it is more preferable that a film thickness is 3 micrometers-30 micrometers. In such a range, the laminate has a sufficient surface hardness and there is little warpage of the laminate due to the cured coating film layer. Further, there is no surface appearance defect due to the inclusion of foreign matter or bubbles.

  The film thickness can be adjusted by the viscosity of the curable mixture, the pressure of the press roll, the press speed, and the like. Moreover, when the said curable mixture contains a solvent, a film thickness can be adjusted by prescribing | regulating solid content concentration.

  The antireflection layer is composed of any material as long as it has a function of suppressing reflected light to 20% or less, preferably 10% or less, more preferably 5% or less of the incident light on the surface of the resin laminate. May be. In order to provide such a function, for example, various methods such as a method of forming a laminated structure of films having two or more different refractive indexes can be cited. It is preferable that the antireflection layer has two or more layers because it is easy to reduce the reflectance.

  In the case of a laminated structure of films having two different refractive indexes, the refractive index of each film is not particularly limited. For example, the refractive index of the outermost surface facing air is 1.3 to 1. It is preferable that the refractive index of the high refractive index layer existing on the substrate side of the low refractive index layer and the low refractive index layer is about 1.6 to 2.0. If it is this range, the reflected light of incident light can fully be suppressed.

  Although the film thickness of a low refractive index layer and a high refractive index layer is not specifically limited, 50 nm-200 nm are preferable respectively, and 70 nm-150 nm are more preferable. If it is this range, the reflected light of the wavelength visually recognized can fully be suppressed.

  Further, the first cured coating film layer may be a high refractive index hard coat layer having a higher refractive index than the antireflection layer, and the antireflection layer may be a single layer of a low refractive index layer. Even in this case, the refractive index of the outermost surface facing the air is a low refractive index layer of about 1.3 to 1.5, and the refractive index of the first cured coating film layer is 1.6 to 2.0. Preferably there is. If it is this range, the reflected light of incident light can fully be suppressed. Thus, when the antireflection layer has a single-layer structure and the refractive index of the first cured coating layer is higher than the refractive index of the antireflection layer, the reflectance of light having a wavelength in the visible light region is set to a certain value or less. Since it becomes easy to do, it can suppress that the specific color of reflected light stands out.

  The film thickness of the low refractive index layer and the high refractive index hard coat layer is not particularly limited, but the film thickness of the low refractive index layer is preferably 50 nm to 200 nm, more preferably 70 nm to 150 nm. The film thickness of the high refractive index hard coat layer is preferably 0.5 μm to 10 μm, and more preferably 1 μm to 7 μm. In such a range, the film has sufficient surface hardness, little warpage of the film by the coating layer, and good appearance.

  Further, when the first cured coating layer is a high refractive index hard coat layer and the antireflection layer is a single layer of a low refractive index layer, the refractive index of the adhesive layer described below is the refractive index of the high refractive index hard coat layer. An intermediate value between the refractive index and the refractive index of the resin substrate is preferable from the viewpoint of suppressing the interference pattern.

  As a component for forming the low refractive index layer, those having a refractive index of about 1.3 to 1.5 are preferable. For example, a layer mainly composed of a siloxane bond made of a condensation polymerization curable compound such as alkoxysilane or alkylalkoxysilane. Specific examples thereof include those formed from a compound in which a part of the siloxane bond of the siloxane-based resin is substituted with a hydrogen atom, a hydroxyl group, an unsaturated group, an alkoxyl group, or the like.

  Further, it is preferable to add colloidal silica to the siloxane-based resin layer from the viewpoint of achieving further reduction in the refractive index. Colloidal silica is a colloidal solution in which fine particles of porous silica and / or non-porous silica are dispersed in a dispersion medium. Here, the porous silica is low-density silica in which the inside of the particle is porous or hollow and contains air inside. The refractive index of porous silica is 1.20 to 1.40, which is lower than that of ordinary silica 1.45 to 1.47. Therefore, in order to reduce the refractive index of the low refractive index layer in the present invention, it is more preferable to use porous silica.

Further, a low refractive index layer may be formed by adding colloidal silica to the aforementioned ultraviolet curable mixture and curing it. Further, colloidal silica whose surface is treated with a silane coupling agent may be used.
These curable compounds are cured by irradiating active energy rays such as an electron beam, radiation, and ultraviolet rays, or cured by heating. These curable compounds may be used alone or in combination with a plurality of curable compounds.

The component that forms the high refractive index layer is preferably one having a refractive index of about 1.6 to 2.0, and a metal alkoxide that itself forms a metal oxide by hydrolysis to form a dense film. What was contained can be used. This metal alkoxide has the chemical formula M (OR) m
(In the chemical formula, M represents a metal, R represents a hydrocarbon group having 1 to 5 carbon atoms, and m represents the valence (3 or 4) of the metal M.)
It is preferable that it is shown by these. As the metal M, titanium, aluminum, zirconium, tin, etc., particularly titanium is suitable. Specific examples of the metal alkoxide include titanium methoxide, titanium ethoxide, titanium n-propoxide, titanium isopropoxide, titanium n-butoxide, titanium isobutoxide, aluminum ethoxide, aluminum isopropoxide, aluminum butoxide, aluminum Examples thereof include t-butoxide, tin t-butoxide, zirconium ethoxide, zirconium n-propoxide, zirconium isopropoxide, zirconium n-butoxide and the like.

In addition, the metal alkoxide forming the metal oxide includes a high refractive index metal that is at least one of ZrO ₂ , TiO ₂ , NbO, ITO, ATO, SbO ₂ , In ₂ O ₃ , SnO _2, and ZnO. Addition of oxide fine particles is preferable from the viewpoint of achieving further higher refractive index.

  Furthermore, a high refractive index layer may be formed by adding metal oxide fine particles having a high refractive index to the ultraviolet curable mixture and curing the mixture. Alternatively, surface-treated high refractive index metal oxide fine particles may be used.

  These curable compounds are cured by irradiating active energy rays such as an electron beam, radiation, and ultraviolet rays, or cured by heating. These curable compounds may be used alone or in combination with a plurality of curable compounds.

  Further, as a technique for increasing the refractive index without using fine particles, an active energy ray-curable organic compound having a fluorene skeleton, a sulfur atom, a halogen atom other than fluorine, an aromatic skeleton, or the like can be used. Examples of the organic compound having a fluorene skeleton include fluorene acrylate.

  Next, as the adhesive layer, for example, acrylic resin, chlorinated olefin resin, vinyl chloride-vinyl acetate copolymer resin, maleic acid resin, chlorinated rubber resin, cyclized rubber resin, polyamide resin, Examples thereof include thermoplastic resins such as coumarone indene resin, ethylene-vinyl acetate copolymer resin, polyester resin, polyurethane resin, styrene resin, butyral resin, rosin resin, and epoxy resin.

  Preferably, the polyamide resin is mixed with at least one of a butyral resin, a rosin resin, and an epoxy resin. Alternatively, the polyurethane resin may be mixed with at least one of a butyral resin, a rosin resin, and an epoxy resin, and a mixture of a polyamide resin and a polyurethane resin may be mixed with a butyral resin or a rosin resin. And at least one of epoxy resins may be mixed. In any case, it is possible to obtain an adhesive layer that can be bonded even at a low temperature. The adhesive layer can be formed by a method known per se.

  Since the adhesive layer is made of a thermoplastic resin and the surface layer does not have tackiness, and the transfer film described later can be stored in a roll shape, it is suitable for continuous production and has good productivity.

  The adhesive layer can be formed using an adhesive obtained by dissolving the resin in a solvent. In this case, when the solvent permeates into the first cured coating layer and the interface between the adhesive layer and the cured coating layer disappears, it is preferable that the defect of the interference pattern disappears.

  In addition, fine particles having a high refractive index can be added to the adhesive layer so as to have an intermediate value between the refractive index of the high refractive index hard coat layer and the refractive index of the resin base material.

  Examples of the resin base material include polymethyl methacrylate, polycarbonate, a copolymer having a methyl methacrylate unit as a main component, polystyrene, and a molded product of styrene-methyl methacrylate copolymer. Moreover, you may add a coloring agent, a light-diffusion agent, etc. to the resin base material. The thickness of the resin laminate is preferably 0.2 mm or more from the viewpoint of mechanical strength, and preferably 10 mm or less from the viewpoint of productivity.

  In addition, the resin laminate may be provided with another functional layer such as an antifouling film on the surface of the antireflection layer, if necessary. For example, in the case of forming an antifouling film, a method (wet method) in which a commercially available antifouling paint is applied to a resin substrate and dried, or a physical vapor deposition method such as a vapor deposition method or a sputtering method, etc. are mentioned. It is done. The surface of the antireflection layer may be flat or matte.

  Next, the manufacturing method of the resin laminated body in this invention is demonstrated in detail.

  The method for producing a resin laminate of the present invention is a method for obtaining a laminate using a transfer film, and has a higher productivity and surface compared to conventional methods such as dipping, roll coating, and spin coating. This is advantageous from the viewpoint of appearance.

  The transfer film will be described in detail.

  As the transparent film, a known film can be used. In addition, a film having peelability is preferable, but if the peelability is insufficient, a peel layer may be provided on the surface of the film.

  For example, polyethylene terephthalate film, polypropylene film, polycarbonate film, polystyrene film, polyamide film, polyamideimide film, polyethylene film, synthetic resin film such as polyvinyl chloride film, cellulose film such as cellulose acetate film, cellophane paper, glassine paper, Examples of the transparent film include film-like materials such as Western paper, Japanese paper, etc., or composite film-like materials, composite sheet-like materials, etc., and those provided with a release layer. The transparent film transmits active energy rays.

  The thickness of the transparent film is not particularly limited, but is preferably 4 μm or more, more preferably 12 μm or more, further preferably 30 μm or more, and more preferably 500 μm or less from the viewpoint of easy production of a transfer film free from wrinkles and cracks. Preferably, it is 150 μm or less, more preferably 120 μm or less.

  When the peelability of these transparent films is insufficient, a release layer may be formed. As a release layer forming material, a polymer or wax that forms a known release layer can be appropriately selected and used. As a method for forming the release layer, for example, paraffin wax, acrylic, urethane, silicon, melamine, urea, urea-melamine, cellulose, benzoguanamine, and the like and surfactants alone or these may be used. A paint dissolved in an organic solvent or water containing the mixture of the above as a main component is applied onto the base film by a normal printing method such as a gravure printing method, a screen printing method or an offset printing method, and dried (thermosetting). Curable resin, UV curable resin, electron beam curable resin, radiation curable resin and the like formed by curing). There is no restriction | limiting in particular as thickness of a peeling layer, It employ | adoptes suitably from the range of about 0.1-3 micrometers. If the release layer is too thin, it will be difficult to peel off, and conversely if the release layer is too thick, it will be easy to peel off and the layers on the film will be detached before transfer, which is not preferable.

  Next, a transfer film can be prepared by laminating the antireflection layer, the first cured coating layer, and the adhesive layer in this order on the release layer by a known coating layer forming method. This transfer film is usually wound into a roll.

  When the transfer film is wound into a roll, it is wound so that the side on which the above-described antireflection layer, first cured coating layer, and adhesive layer (hereinafter collectively referred to as “transfer layer”) are formed is located on the inside. What was taken and what was wound up so that it may be located outside can be produced. By properly using these two types of wound transfer films, warpage of the obtained laminate can be suppressed.

  For example, when the second cured coating layer has a large polymerization shrinkage due to UV curing and the cured coating layer side of the resin substrate is warped so as to be inside the arc, the winding is performed so that the transfer layer is positioned inside. By using the taken transfer film, it is possible to suppress warping of the obtained laminate. Here, the “arc” means “the arc of the laminate warped in an arc”.

  Moreover, when using the laminated body which provided the cured coating film (hard-coat) layer on the single side | surface by the cast polymerization method as a resin base material, the curvature that a hard-coat layer side becomes the outer side of a circular arc may arise. In this case, when the transfer layer is formed on the side where the hard coat layer is not provided, a transfer film wound up so that the transfer layer is positioned on the inner side is used, and the urethane-based macro with extremely small curing shrinkage described above. It becomes possible to suppress warping of the laminate obtained by forming the second cured coating film layer using a monomer or the like as appropriate.

  By using such a method, even when the film thickness of the cured coating film layer is large, it is possible to easily produce a laminate having a small warpage.

  As a 1st process, a solventless type ultraviolet curable mixture is apply | coated on this contact bonding layer of the obtained transfer film, and an application layer is formed. Here, the content of the solvent in the solventless ultraviolet curable mixture is less than 1% by mass with respect to the mixture.

  As a method for forming the coating layer, a solvent-free ultraviolet curable mixture is applied in a line and perpendicular to the film traveling direction (feeding direction) by roll coating, bar coating, slit die, or the like. Is preferably formed. That is, it is preferable to apply the supply unit for applying the ultraviolet curable mixture while moving the supply unit in a direction perpendicular to the traveling direction of the film and parallel to the application surface of the film. When the coating layer is formed on the film, optical distortion may occur due to non-uniform dissolution of the substrate if the coating layer is applied in parallel and linearly to the traveling direction of the film.

  Moreover, in order to prevent air entrainment at the time of bonding, it is preferable to apply an excessive amount of an ultraviolet curable mixture on the film.

  Subsequently, the said application layer side is affixed on a resin base material at a 2nd process. As a method of attaching, there is a method of pressure bonding with a rubber roll.

  As a method of bonding the film on which the coating layer is formed and the resin base material, a method in which the film and the resin base material are transported and pressure bonded with the rubber roll, and the film and the resin base material are overlapped. For example, there may be mentioned a method in which the rubber rolls are pressed and bonded together in a state where they are in contact. The former method in which the film and the resin base material are bonded together is preferably used in the continuous method, and the latter film and the resin base material are bonded together with a rubber roll in a state where the latter film and the resin base material are overlapped. It is preferable that the method of applying and bonding is employed in the batch method.

  In addition, it describes in detail about "application | coating to a perpendicular | vertical and linear form with respect to the advancing direction of a film" described by the formation method of the above-mentioned application layer.

  When the film and the resin base material are transported, and the method of pressure bonding with the rubber roll is employed, the traveling direction of the film and the resin base material is the same. On the other hand, it means that the coating is applied in a vertical direction and linearly.

  On the other hand, when the film and resin base material are overlaid and the method of pressure bonding with a rubber roll is adopted, the film traveling direction is the direction in which the resin base material is overlaid and integrated and conveyed. Since it is the same as the traveling direction of the resin base material, it is described here as the traveling direction of the film for convenience. With respect to the traveling direction of the film, the mixture is previously applied in a vertical direction and linearly on the adhesive layer to form a coating layer.

  In the second step, the surface temperature of the resin base material is preferably set to 40 ° C to 100 ° C. At a temperature in such a range, the adhesion is good, there is no decrease in hardness due to excessive dissolution of the base material, and there is little yellowing of the coating film. The surface temperature of the resin substrate can be adjusted by the set temperature of the heating unit, the heating time, and the like. As a method for measuring the temperature of the resin substrate, a known method such as a non-contact type surface thermometer can be used. The active energy ray-curable mixture that forms the second cured coating film layer preferably has a viscosity of 15 to 120 mPa · s at the same temperature as the surface temperature of the resin substrate. In such a range, the adhesion is good and there is no optical distortion. The viscosity range can be adjusted by appropriately adjusting the composition and temperature of the composition. Further, there is no surface appearance defect due to the entrapment of bubbles. The viscosity can be adjusted by the composition of the curable mixture.

  After the transfer film is attached to the mold in the second step, as a third step, the active energy ray is irradiated through the transfer film to cure the active energy ray-curable mixture in the coating layer. It is set as 2 cured coating film layers. As the active energy ray, ultraviolet rays are preferable as described above. In the case of ultraviolet irradiation, an ultraviolet lamp may be used. Examples of the ultraviolet lamp include a high pressure mercury lamp, a metal halide lamp, and a fluorescent ultraviolet lamp. Curing by ultraviolet irradiation may be performed in one step through a transfer film, or the first step is performed through a transfer film (third step), and the transparent film is peeled off (fourth step). Step), and then curing may be carried out in two stages, for example, by further irradiating ultraviolet rays to carry out the second stage curing. When a curable resin other than the ultraviolet curable mixture is used, for example, an active energy ray such as an electron beam or radiation may be appropriately selected and cured by irradiation through a transfer film.

  In the present invention, the curable mixture is cured in the third step to form a second cured coating layer, and then the second cured coating layer and adhesive layer provided on the resin substrate as the fourth step. The transparent film of the transfer film is peeled off leaving the first cured coating film layer and the antireflection layer. That is, the adhesive layer, the first cured coating layer, and the antireflection layer of the transfer film are transferred onto the second cured coating layer on the resin substrate. The release layer remains on the transparent film side.

  The resin laminate obtained by the above method is suitable for applications such as a display front plate.

EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited to these. Here, the abbreviations of the compounds used in Examples and Comparative Examples are as follows.
“TAS”: Condensation mixture of succinic acid / trimethylolethane / acrylic acid in a molar ratio of 15: 4 (manufactured by Osaka Organic Chemical Industry Co., Ltd.)
“C6DA”: 1,6-hexanediol diacrylate (manufactured by Osaka Organic Chemical Industry Co., Ltd.)
“M305”: Pentaerythritol triacrylate M-305 (manufactured by Toagosei Co., Ltd.)
“M309”: Trimethylolpropane triacrylate M-309 (manufactured by Toagosei Co., Ltd.)
“M400”: Dipentaerythritol hexaacrylate M-400 (manufactured by Toagosei Co., Ltd.)
"Art Resin SUX-1": Urethane macromonomer (manufactured by Negami Sangyo Co., Ltd.)
“OPTOOL AR”: Fluorine-based low refractive index acrylate, solid concentration 15% by weight, methyl isobutyl ketone solution (manufactured by Daikin Chemicals Sales Co., Ltd.)
“Ogsol EA-F5010”: fluorene skeleton-containing acrylate (Osaka Gas Chemical Co., Ltd.)
“Dianar BR-80”: acrylic resin (manufactured by Mitsubishi Rayon Co., Ltd.).
“DAROCUR TPO”: 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide (manufactured by Ciba Japan)
“Irgacure 184”: 1-hydroxy-cyclohexyl-phenyl ketone (manufactured by Ciba Japan Co., Ltd.)
“Acrylite EX001”: acrylic resin plate (manufactured by Mitsubishi Rayon Co., Ltd.).
“Acrylite MR100”: polymethyl methacrylate with a single-side hard coat layer (manufactured by Mitsubishi Rayon Co., Ltd.).

In addition, evaluation of the physical property in an Example was performed based on the following method.
<Viscosity measurement method>
The viscosity of a B-type viscometer at 6 rpm was measured at each temperature. The viscosity was measured at the same temperature as the substrate temperature.
<Measurement of temperature of resin substrate>
The substrate was warmed and preheated and measured with a non-contact type surface thermometer (manufactured by CHINO Co., Ltd., handheld radiation thermometer IR-TA).
<Total light transmittance and haze>
Using Nippon Denshoku HAZE METER NDH2000 (trade name), the total light transmittance is measured based on the measurement method shown in JIS K7361-1, and the haze is measured based on the measurement method shown in JIS K7136. did.
<Abrasion resistance>
The haze change (Δhaze) before and after the abrasion test was evaluated. In other words, a circular pad with a diameter of 25.4 mm equipped with # 000 steel wool was placed on the cured coating layer surface of the laminate, and under a load of 500 g, a 20 mm distance was reciprocally scratched 10 times. The difference in haze value afterwards was obtained from the following formula (1).
[Δhaze (%)] = [haze value after abrasion (%)] − [haze value before abrasion (%)] (1)
In addition, the number of scratches on the sample after the test was counted.
<Antireflection performance evaluation>
The back surface of the sheet is roughened with sandpaper and then applied with a matte black spray. This is used as a sample, and a spectrophotometer (“U-4000” manufactured by Hitachi, Ltd.) is used, with an incident angle of 5 ° and a wavelength of 380. The reflectance of the surface of the sample was measured in accordance with the measurement method shown in JIS R3106 in the range of ˜780 nm.
<Adhesion evaluation>
The cross-cut test (JIS K5600-5-6) was used for evaluation. The test was repeated 4 times, and the total of 4 times of the number of the remaining portions without peeling was displayed among 25 locations.
<Appearance evaluation of surface layer>
The presence or absence of bubbles and foreign matters on the sample surface was confirmed visually.
○: Bubbling bite, no foreign matter △: No bubble biting but foreign matter ×: Bubble biting, foreign matter <optical distortion>
The presence or absence of distortion of the sample was confirmed visually.
○: No distortion ×: There is distortion.
<Evaluation of warpage of resin laminate>
The amount of warpage of the 30 cm × 30 cm resin laminate after being left for 15 hours in an environment of 80 ° C. was measured. The amount of warpage was measured by placing a sample on a flat plate and measuring the distance from the flat plate to the warped sample.
○: Warpage amount 5 mm or less ×: Warpage amount 5 mm or more <Refractive index and film thickness measurement method>
About the antireflection layer and the cured coating film layer, the refractive index and film thickness in a 594 nm laser were measured using (manufactured by Metricon, film thickness / refractive index measuring device, model 2010, prism coupler).
<Thickness measurement method>
The film thickness of the sample without measuring the refractive index was measured by cutting the sample to a thickness of 100 nm with a microtome and observing with a transmission electron microscope. The transmission electron microscope was measured using JEOL JEM-1010.
[Example 1]
To the adhesive layer side of the antireflection transfer film (manufactured by Oike Kogyo Co., Ltd., trade name: STEP PAR-1; film (PET film), release layer, antireflection layer, cured coating layer, adhesive layer in that order) TAS 35 parts by mass, C6DA 30 parts by mass, M305 10 parts by mass, M400 25 parts by mass, DAROCUR
A paint composed of an ultraviolet curable mixture composed of 2 parts by mass of TPO was applied in a line perpendicular to the traveling direction of the film, and a planar coating layer was formed using a bar coater (No. 50). In addition, the antireflection transfer film was not used as it was wound up in a roll shape, but was cut out from a portion wound up in a roll shape, and used what was stored in a flat shape. .

  Next, on the acrylic resin base material (Acrylite EX001) having a thickness of 2 mm heated to 60 ° C., the antireflection transfer film having the coating layer formed thereon is placed with the coating layer facing the resin base material side. After the superposition, the film is passed through a fixed rubber roll having a JIS hardness of 40 ° at a constant speed (traveling direction of the film), and the coating film containing the ultraviolet curable mixture is excessively thick so that the thickness becomes 15 μm. While squeezing out the paint, it was pressure-bonded so as not to contain bubbles.

  In addition, the thickness of the coating film containing the ultraviolet curable mixture was calculated from the supply amount and development area of the ultraviolet curable mixture.

  Next, after 120 seconds had passed while heating to 60 ° C., UV light was irradiated through the transfer film through a position 20 cm below the metal halide lamp with an output of 9.6 kW at a speed of 2.5 m / min. Then, the ultraviolet curable mixture was cured to form a second cured coating film layer.

  Thereafter, when the transfer film is peeled off, the antireflection layer, the first cured coating layer and the adhesive layer are all transferred to the second cured coating layer, and the antireflection layer and the first cured coating layer are transferred. Thus, a resin laminate having a configuration of an adhesive layer, a second cured coating film layer, and an acrylic resin base material was obtained. The film thickness of the 1st cured coating film layer of the obtained resin laminated body was 2 micrometers, and the film thickness of the 2nd cured coating film layer was 13 micrometers.

The obtained antireflection laminate had a total light transmittance of 94% and a haze of 0.2%, was excellent in transparency, and had no appearance defect due to optical distortion. Furthermore, it had a good surface layer without appearance defects due to foreign matters, biting of bubbles, and the like. The haze increment after abrasion of the antireflection layer was 0.1%, and the number of scratches was 3. The minimum reflectance was 1% at a wavelength of 580 nm. As a result of the adhesion test, the coating film was not peeled off and the adhesion was good. As a result of the warpage test, the amount of warpage was less than 5 mm. The results are shown in Table 1.
[Example 2]
A resin laminate was produced in the same manner as in Example 1 except that the film thickness of the second cured coating film layer was changed as shown in Table 1 in Example 1. The results are shown in Table 1.
[Example 3]
A resin laminate was produced in the same manner as in Example 1 except that the film thickness of the second cured coating film layer was changed as shown in Table 1 in Example 1. The results are shown in Table 1.
[Example 4]
In Example 1, a resin laminate was produced in the same manner as in Example 1 except that the temperature of the resin base material was changed as shown in Table 1. The results are shown in Table 1.
[Example 5]
A resin laminate was prepared in the same manner as in Example 1 except that the ultraviolet curable mixture was changed as shown in Table 1 in Example 1. The results are shown in Table 1.
[Example 6]
A resin laminate was prepared in the same manner as in Example 1 except that the ultraviolet curable mixture was changed as shown in Table 1 in Example 1. The results are shown in Table 1.
[Example 7]
A resin laminate was prepared in the same manner as in Example 1 except that the ultraviolet curable mixture was changed as shown in Table 1 in Example 1. The results are shown in Table 1.
[Example 8]
In Example 7, a resin laminate was produced in the same manner as in Example 7 except that the temperature of the resin base material was changed as shown in Table 1. The results are shown in Table 1.
[Example 9]
A resin laminate was prepared in the same manner as in Example 1 except that the ultraviolet curable mixture was changed as shown in Table 1 in Example 1. The results are shown in Table 1.
[Example 10]
In Example 1, an antireflection transfer film (made by Oike Kogyo Co., Ltd., trade name: STEP PAR-2; film (PET film), release layer, antireflection layer, cured coating layer, and adhesive layer was laminated in this order. A resin laminate was produced in the same manner as in Example 1 except that the change was made to). The results are shown in Table 1.
[Example 11]
A resin laminate was produced in the same manner as in Example 1 except that the resin base material was changed to a 2 mm thick polycarbonate resin (trade name: Panlite AD-5503, manufactured by Teijin Chemicals Ltd.) in Example 1. did. The results are shown in Table 1.
[Example 12]
A resin laminate was produced in the same manner as in Example 1 except that the film thickness of the second cured coating film layer was changed as shown in Table 1 in Example 1. Since the film thickness of the second cured coating film layer was less than 3 μm, the hardness was insufficient. In addition, foreign matter defects on the surface layer occurred. The results are shown in Table 2.
[Example 13]
A resin laminate was produced in the same manner as in Example 1 except that the film thickness of the second cured coating film layer was changed as shown in Table 1 in Example 1. Since the film thickness of the 2nd cured coating film layer was 30 micrometers or more, curvature generate | occur | produced. The results are shown in Table 2.
[Example 14]
In Example 1, a resin laminate was produced in the same manner as in Example 1 except that the surface temperature of the substrate was changed as shown in Table 1. Since the substrate surface temperature was less than 40 ° C., the adhesion was poor. The results are shown in Table 2.
[Example 15]
In Example 1, a resin laminate was produced in the same manner as in Example 1 except that the surface temperature of the substrate was changed as shown in Table 1. Since the substrate surface temperature was 100 ° C. or higher, excessive dissolution of the substrate occurred and the hardness was insufficient. Moreover, since the viscosity of the ultraviolet curable mixture was 15 mPa · s or less, optical distortion occurred. The results are shown in Table 2.
[Example 16]
A resin laminate was produced in the same manner as in Example 1 except that the ultraviolet curable mixture composition was changed as shown in Table 1 in Example 1. Since the viscosity of the ultraviolet curable mixture was 120 mPa · s or more, the adhesion was poor. In addition, foreign matter defects on the surface layer occurred. The results are shown in Table 2.
[Example 17]
In Example 1, a resin laminate was produced in the same manner as in Example 1 except that the temperature was increased and the viscosity of the ultraviolet curable mixture was changed as shown in Table 2. Since the viscosity of the ultraviolet curable mixture was 15 mPa · s or less, optical distortion occurred.
[Example 18]
In Example 1, resin was applied in the same manner as in Example 1 except that the film was applied in parallel and linearly with respect to the film traveling direction, and a planar coating layer was formed using a No. 50 bar coder. A laminate was produced. When a planar coating layer was formed using a bar coder, a portion that was not partially coated was formed. Therefore, streak-like optical distortion occurred in the resin laminate. The results are shown in Table 2.
[Example 19]
In Example 1, a resin laminate was produced in the same manner as in Example 1 except that the film thickness and composition of the second cured coating layer were changed as shown in Table 3. Although the film thickness of the 2nd cured coating film layer was 30 micrometers or more, since the urethane macromonomer (Art Resin SUX-1) was used, curvature did not generate | occur | produce. The results are shown in Table 3.
[Example 20]
In Example 13, a resin laminate was produced in the same manner as in Example 13 except that the antireflection transfer film was rolled up around a paper tube with the following contents.
・ Paper tube: 6 inches in diameter ・ PET base material thickness: 100 μm
-Winding length: 500m
-Direction of winding of transfer layer: Rolled up so that transfer layer is located on the inner side. Even when the thickness of the second cured coating film layer was 30 µm or more, no warpage occurred in the resin laminate. The results are shown in Table 3.
[Example 21]
In Example 20, using acrylite MR100 as the resin base material, transfer to the surface where the hard coat layer was not formed via the second cured coating film layer having the film thickness and composition as shown in Table 3 A resin laminate was produced in the same manner as in Example 20 except that the layer was transferred. It was possible to cancel the warpage of the acrylite MR100 itself, that is, the warp that the antireflection layer forming surface side was inside the arc. The results are shown in Table 31.
[Example 22]
In Example 21, a resin laminate was produced in the same manner as in Example 21 except that the winding direction of the transfer layer was changed to the outside of the roll. There was no effect of suppressing warpage, and warping of the laminate occurred. The results are shown in Table 3.
[Example 23]
A resin laminate was prepared in the same manner as in Example 1 except that the antireflection transfer film in Example 1 was changed to the following single-layer antireflection film having only a low refractive index layer.
(Adjustment of low refractive index paint)
Add MIBK (methyl isobutyl ketone) to OPTOOL AR (solid content 15% by weight), dilute to 1% by weight solid content, and add 5 parts by weight of Irgacure 184 to 100 parts by weight of OPTOOL AR. Then, a low refractive index paint was prepared.
(Adjustment of high refractive index paint)
MIBK (methyl isobutyl ketone) is added to Ogsol EA-F5010, diluted to a solid content of 50% by mass, and 5 parts by mass of Irgacure 184 is added to 100 parts by mass of the solid content of Ogsol EA-F5010. Rate paint was adjusted.
(Adjustment of adhesive layer forming paint)
50 parts by weight of Dianal BR-80 and 166 parts by weight of zirconia sol (manufactured by Sumitomo Osaka Cement Co., Ltd., solid content concentration (zirconia) 30% by weight methyl ethyl ketone dispersion sol) are mixed, and MIBK (methyl isobutyl ketone) is further added. The solid content concentration (based on the total solid content of Dianar BR-80 and zirconia of 100 parts by mass) was adjusted to 2% by mass.
(Preparation of single-layer antireflection transfer film)
The low refractive index coating material was applied to a 100 μm PET film with a melamine release layer (product name AC-J, manufactured by Reiko Co., Ltd.) using a No. 4 bar coater and dried at 80 ° C. for 5 minutes. Thereafter, a low refractive index layer was formed by passing a position 20 cm below the 9.6 kW high-pressure mercury lamp at a speed of 2.5 m / min. Its refractive index was 1.38.

  Next, the high refractive index paint was applied onto the low refractive index layer using a No. 4 bar coater and dried at 80 ° C. for 5 minutes. Thereafter, a high refractive index hard coat layer was formed by passing a position 20 cm below the 9.6 kW high-pressure mercury lamp at a speed of 2.5 m / min. Its refractive index was 1.60.

  Subsequently, an adhesive layer forming paint was applied onto the high refractive index layer using a No. 4 bar coater and dried at 80 ° C. for 5 minutes to form an adhesive layer.

From the film thickness measurement result of the obtained resin laminate, the film thickness of the low refractive index layer was 100 nm, the film thickness of the high refractive index hard coat layer was 4 μm, and the film thickness of the adhesive layer was 200 nm. The results are shown in Table 3. Since it was a single-layer antireflection laminate, the reflection color was thinner than the laminates of the other examples.
[Comparative Example 1]
The adhesive layer side of the antireflection transfer film (Oike Kogyo Co., Ltd., trade name: STEP PAR-1) is the methacrylic resin substrate (Mitsubishi Rayon Co., Ltd., trade name: Acrylite EX001) side, and they are laminated together After that, it was pressed using a hydraulic molding machine (manufactured by Shoji Steel Co., Ltd.), and a pressure of 10 MPa was applied, and the upper and lower set temperatures were 120 ° C., and the pressure was applied for 10 minutes. When a thermocouple was attached to the film surface and the film surface temperature was measured, the surface temperature after 10 minutes was 100 ° C. Then, after cooling to 30 degreeC in the state which applied the pressure, the film was peeled. Since the second cured coating film layer did not exist in the obtained resin laminate, the hardness was insufficient. In addition, foreign matter defects on the surface layer occurred. Furthermore, the adhesion between the first cured coating film layer and the resin substrate was not sufficient. The results are shown in Table 2.
[Comparative Example 2]
In Example 1, except that an antireflection transfer film having no adhesive layer (made by Oike Kogyo Co., Ltd., trade name: STEP PAR-1 was immersed in acetone for 10 minutes and the adhesive layer was removed) was used. In the same manner as in Example 1, a resin laminate was produced. Since it did not have an adhesive layer, the adhesion was insufficient. The results are shown in Table 2.

  The resin laminate of the present invention is a front panel of various displays such as a CRT, a liquid crystal display, an organic EL display, a plasma display, and a projection television, and in front of an information display unit of an information terminal such as a mobile phone, a portable music player, and a mobile personal computer It can be suitably used for a face plate or the like.

Claims (5)

  A solventless active energy ray-curable mixture is applied on the adhesive layer of the transfer film in which a release layer, an antireflection layer, a first cured coating layer, and an adhesive layer are sequentially formed on one side of the transparent film. A first step of forming a coating layer, a second step of attaching the coating layer side to a resin substrate, and curing the active energy ray-curable mixture in the coating layer to form a second cured coating layer And a fourth step of peeling off the transparent film leaving the second cured coating layer, the adhesive layer, the first cured coating layer, and the antireflection layer laminated on the resin substrate. A process for producing a resin laminate comprising the steps.   The method for producing a resin laminate according to claim 1, wherein the film thickness of the first cured coating film layer is 0.5 µm to 10 µm, and the film thickness of the second cured coating film layer is 0.5 µm to 40 µm.   In the second step, the surface temperature of the resin substrate is set to 40 ° C. to 100 ° C., and the viscosity of the active energy ray-curable mixture forming the second cured coating film layer at the same temperature as the surface temperature is 15 to 120 mPa · s. The method for producing a resin laminate according to claim 1 or 2.   The method for producing a resin laminate according to claim 1, wherein the antireflection layer has a structure of two or more layers. The method for producing a resin laminate according to claim 1, wherein the antireflection layer has a single-layer structure, and the refractive index of the first cured coating film layer is higher than the refractive index of the antireflection layer.