# US 11,306,188 B2 · Optical film and method for manufacturing optical film

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- Number: US 11,306,188 B2
- Document ID: US11306188B2
- Status: Granted
- Kind: B2
- Application number: 16/437,378
- Filed: 2019-06-11
- Published: 2019-10-10
- Granted: 2022-04-19
- Earliest claimed: 2016-12-22
- Assignees: FUJIFILM Corporation
- Applicants: FUJIFILM Corporation
- Inventors: Ayako Matsumoto; Shuntaro Ibuki; Chihiro Masuda
- Web page: https://patentgrep.com/patent/US11306188B2

## CPC

- C08J 7/046: Forming abrasion-resistant coatings; Forming surface-hardening coatings
- B05D 3/12: by mechanical means
- B29C 43/24: Calendering
- B32B 7/02: Physical, chemical or physicochemical properties
- C08J 7/0427: {with only one layer of a composition containing a polymer binder (with more layers C08J7/042)}
- C09D 5/004: {Reflecting paints; Signal paints}
- C09D 7/61: inorganic
- C09D 135/02: Homopolymers or copolymers of esters (C09D135/06, C09D135/08 take precedence)
- G02B 1/14: Protective coatings, e.g. hard coatings
- C08J 2377/10: Polyamides derived from aromatically bound amino and carboxyl groups of amino carboxylic acids or of polyamines and polycarboxylic acids
- C08J 2433/04: esters
- Y10T 428/24355: Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An optical film has a base material and a hardcoat layer, in which a pencil hardness is 2H or higher, the number of times of folding endurance measured by an MIT tester is 1000 or more, an incident ray is made incident on the optical film from −60° with respect to a normal direction of the optical film, an angle width within which 10% of outgoing ray peak intensity is obtained is 6° or less, and an intensity of outgoing ray at 50° from the normal direction is 1% or less of the outgoing ray peak intensity. A method for manufacturing an optical film has a step of applying a hardcoat layer forming composition to a base material to provide a coating film, and a step of curing the coating film while bringing the coating film into contact with one smooth metal roll.

## Claims

### Claim 1

An optical film comprising:
a base material; and
a hardcoat layer,
wherein a pencil hardness measured according to JIS K 5600-5-4:1999 is 2H or higher,
the number of times of folding endurance measured by an MIT tester according to JIS P 8115:2001 is 1000 or more, and
wherein the reflection characteristics measured using a three-dimensional gonio-spectrophotometric color measurement system is that;
in a case where an incident ray is made incident on the optical film from −60° with respect to a normal direction of the optical film, an angle width within which 10% of outgoing ray peak intensity is obtained is 6° or less, and an intensity of an outgoing ray at 50° from the normal direction is 1% or less of the outgoing ray peak intensity.

### Claim 2 (depends on 1)

The optical film according to claim 1,
wherein a surface roughness of an outermost surface on a side on which the hardcoat layer is laminated is 5 nm or less.

### Claim 3 (depends on 1)

The optical film according to claim 1,
wherein a surface roughness of an outermost surface on a side on which the hardcoat layer is laminated is 2 nm or less.

### Claim 4 (depends on 1)

The optical film according to claim 1,
wherein the hardcoat layer includes inorganic particles, and particle diameters of the inorganic particles have a single distribution.

### Claim 5 (depends on 4)

The optical film according to claim 4,
wherein a filling rate of the inorganic particles in the hardcoat layer is 55% by volume or less.

### Claim 6 (depends on 1)

The optical film according to claim 1, further comprising:
a scratch resistant layer on a surface of the hardcoat layer opposite to the base material.

### Claim 7 (depends on 1)

The optical film according to claim 1,
wherein the number of times of folding endurance measured by an MIT tester according to JIS P 8115:2001 is 10000 or more.

### Claim 8 (depends on 1)

The optical film according to claim 1,
wherein the pencil hardness measured according to JIS K 5600-5-4:1999 is 4H or higher.

### Claim 9

A method for manufacturing an optical film including a base material, and a hardcoat layer, in which a pencil hardness measured according to JIS K 5600-5-4:1999 is 2H or higher, the number of times of folding endurance measured by an MIT tester according to JIS P 8115:2001 is 1000 or more, and
wherein the reflection characteristics measured using a three-dimensional gonio-spectrophotometric color measurement system is that;
in a case where an incident ray is made incident on the optical film from −60° with respect to a normal direction of the optical film, an angle width within which 10% of outgoing ray peak intensity is obtained is 6° or less, and an intensity of an outgoing ray at 50° from the normal direction is 1% or less of the outgoing ray peak intensity, the method comprising:
(i-1) applying a hardcoat layer forming composition to the base material to provide a coating film; and
(iii-1) curing the coating film while bringing the coating film into contact with one smooth metal roll.

### Claim 10 (depends on 9)

The method for manufacturing an optical film according to claim 9,
wherein a curing rate of the coating film immediately before the step (iii-1) is 20% or less.

### Claim 11 (depends on 9)

The method for manufacturing an optical film according to claim 9, further comprising:
between the steps (i-1) and (iii-1),
(ii-1) curing a surface layer of the coating film to set a curing rate of the surface layer of the coating film to 50% or more.

### Claim 12 (depends on 9)

The method for manufacturing an optical film according to claim 9,
wherein a surface roughness of the metal roll in the step (iii-1) is 40 nm or less.

### Claim 13

A method for manufacturing an optical film including a base material, and a hardcoat layer, in which a pencil hardness measured according to JIS K 5600-5-4:1999 is 2H or higher, the number of times of folding endurance measured by an MIT tester according to JIS P 8115:2001 is 1000 or more, and
wherein the reflection characteristics measured using a three-dimensional gonio-spectrophotometric color measurement system is that;
in a case where an incident ray is made incident on the optical film from −60° with respect to a normal direction of the optical film, an angle width within which 10% of outgoing ray peak intensity is obtained is 6° or less, and an intensity of an outgoing ray at 50° from the normal direction is 1% or less of the outgoing ray peak intensity, the method comprising:
(i-2) applying a hardcoat layer forming composition to the base material to provide a coating film;
(ii-2) curing the coating film; and
(iii-2) performing a calender treatment.

### Claim 14 (depends on 13)

The method for manufacturing an optical film according to claim 13,
wherein the step (ii-2) is setting a curing rate of the coating film to 10% to 80%.

### Claim 15 (depends on 13)

The method for manufacturing an optical film according to claim 13,
wherein the calender treatment in the step (iii-2) is performed using two rolls, a line speed is 20 m/min or more, a temperature of at least one roll is 80° C. or higher, a nip pressure is 100 kg/cm or higher, and the number of nips is 1 or more.

### Claim 16 (depends on 13)

The method for manufacturing an optical film according to claim 13,
wherein the calender treatment in the step (iii-2) is performed using two rolls, one of the two rolls close to the coating film is a metal roll, and a surface roughness of the metal roll is 40 nm or less.