# US 2021/0278568 A1 · Anti-glare and anti-reflective transparent substrate and method for manufacturing same

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- Number: US 2021/0278568 A1
- Document ID: US20210278568A1
- Status: Published application
- Kind: A1
- Application number: 16/337,277
- Filed: 2017-11-01
- Published: 2021-09-09
- Earliest claimed: 2016-11-07
- Assignees: Fukuvi Chemical Industry Co., Ltd.
- Applicants: Fukuvi Chemical Industry Co., Ltd.
- Inventors: Yukihiro YANAGAWA; Masahiro SAITO; Shinichi NOMURA; Yuya MATSUZAKI
- Web page: https://patentgrep.com/patent/US20210278568A1

## CPC

- G02B 1/118: having sub-optical wavelength surface structures designed to provide an enhanced transmittance, e.g. moth-eye structures
- G02B 5/0268: {characterized by the fabrication or manufacturing method}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 27/08: of synthetic resin
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/365: {comprising polycarbonates}
- B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence)
- G02B 1/111: using layers comprising organic materials
- G02B 5/0221: {the surface having an irregular structure (G02B5/0226 takes precedence)}
- G02B 5/0278: {used in transmission}
- G02B 5/0294: {adapted to provide an additional optical effect, e.g. anti-reflection or filter}
- B32B 2037/243: {Coating}
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2307/412: Transparent
- B32B 2307/418: Refractive
- B32B 2307/538: Roughness
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2310/0831: using UV radiation
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

The present invention provides a transparent substrate (10) in which the transparent substrate (10) is formed by fully curing a semi-cured product layer (13s) of an intermediate laminate (1) which includes a base material (11) having light-transmitting properties, an anti-reflective layer (14) provided on at least one surface of the base material (11), and the semi-cured product layer (13s) that is provided between the base material (11) and the anti-reflective layer (14) and is formed of a semi-cured product of an ultraviolet-curable resin composition, a surface of the anti-reflective layer (14) has an irregular uneven structure, and a surface of the uneven structure has an arithmetic mean roughness Ra of 0.01 to 1.00 μm and am mean unevenness period RSm of 1 to 30 μm, the anti-reflective layer (14) includes a low refractive index layer (14a) having a refractive index of 1.47 or less and a thickness of 50 to 200 nm at an outermost layer, a Young's modulus of the semi-cured product layer (13s) is 0.1 to 2.5 GPa, and a thickness of the semi-cured product layer (13s) after being fully cured is 1.0 to 10.0 μm, and a percent elongation of the intermediate laminate 1 is 105% to 150%.

## Claims

### Claim 1

A transparent substrate which is formed by fully curing a semi-cured product layer of an intermediate laminate, the intermediate laminate comprising:
a base material having light-transmitting properties,
an anti-reflective layer provided on at least one surface of the base material, and
the semi-cured product layer that is provided between the base material and the anti-reflective layer and is formed of a semi-cured product of an ultraviolet-curable resin composition,
wherein a surface of the anti-reflective layer has an irregular uneven structure, and a surface of the uneven structure has an arithmetic mean roughness Ra of 0.01 to 1.00 μm and a mean unevenness period RSm of 1 to 30 μm,
the anti-reflective layer includes a low refractive index layer having a refractive index of 1.47 or less and a thickness of 50 to 200 nm at an outermost layer,
a Young's modulus of the semi-cured product layer is 0.1 to 2.5 GPa, and a thickness of the semi-cured product layer after being fully cured is 1.0 to 10.0 μm, and
a percent elongation of the intermediate laminate is 105% to 150%.

### Claim 2 (depends on 1)

The transparent substrate according to claim 1,
wherein the ultraviolet-curable resin composition contains a tri- or lower functional urethane acrylate, a silane coupling agent, and a metal chelate compound.

### Claim 3 (depends on 2)

The transparent substrate according to claim 2,
wherein the ultraviolet-curable resin composition further contains silica particles.

### Claim 4 (depends on 2)

The transparent substrate according to claim 2,
wherein the ultraviolet-curable resin composition further contains a tetra- or higher functional urethane acrylate.

### Claim 5 (depends on 1)

The transparent substrate according to claim 1,
wherein the anti-reflective layer has a multi-layer structure including, in order from the base material side, a medium refractive index layer having a refractive index of more than 1.47 and less than 1.65 and a thickness of 50 to 120 nm, a high refractive index layer having a refractive index of 1.60 or more and higher than the refractive index of the medium refractive index layer and a thickness of 50 to 120 nm, and the low refractive index layer.

### Claim 6 (depends on 1)

The transparent substrate according to claim 1, further comprising:
a barrier layer provided between the base material and the semi-cured product layer, the barrier layer containing a tetra- or higher urethane acrylate and having a thickness of 50 to 200 nm.

### Claim 7

A method for manufacturing a transparent substrate, comprising:
a step (b): a step of forming a semi-cured product layer on a base material by applying an ultraviolet-curable resin composition onto at least one surface of the base material having light-transmitting properties and semi-curing the ultraviolet-curable resin composition so as to cause a thickness after full curing to be 1.0 to 10.0 μm;
a step (c): a step of obtaining an intermediate laminate by forming an anti-reflective layer on the semi-cured product layer;
a step (d): a step of, using a transfer mold having an irregular uneven structure on a transfer surface and having an arithmetic mean roughness Ra of the transfer surface of 0.01 to 1.25 μm and a mean unevenness period RSm of 1 to 30 μm, transferring the uneven structure of the transfer surface onto a surface of the anti-reflective layer of the intermediate laminate; and
a step (e): a step of fully curing the semi-cured product layer after the step (d),
wherein a Young's modulus of the semi-cured product layer is 0.1 to 2.5 GPa,
a percent elongation of the intermediate laminate is 105% to 150%, and
the step (c) includes at least a step (c-3) as follows,
the step (c-3): a step of forming a low refractive index layer having a refractive index of 1.47 or less and a thickness of 50 to 200 nm on the semi-cured product layer.

### Claim 8 (depends on 7)

The method for manufacturing a transparent substrate according to claim 7,
wherein, in the step (b), the ultraviolet-curable resin composition is semi-cured by irradiating the ultraviolet-curable resin composition on the base material with ultraviolet rays by a cumulative light amount of 150 to 500 mJ/cm2.

### Claim 9 (depends on 7)

The method for manufacturing a transparent substrate according to claim 7,
wherein, in the step (d), the surface of the anti-reflective layer of the intermediate laminate is subjected to a pressurizing treatment and is transferred using the transfer mold at a pressure of 4 to 38 MPa and a temperature of 60° C. to 150° C.

### Claim 10 (depends on 7)

The method for manufacturing a transparent substrate according to claim 7,
wherein the step (c) further includes a step (c-1) and a step (c-2) as follows before the step (c-3),
the step (c-1): a step of forming a medium refractive index layer having a refractive index of more than 1.47 and less than 1.65 and a thickness of 50 to 120 nm on the semi-cured product layer, and
the step (c-2): a step of forming a high refractive index layer having a refractive index of 1.60 or more and higher than the refractive index of the medium refractive index layer and a thickness of 50 to 120 nm on the medium refractive index layer.

### Claim 11 (depends on 7)

The method for manufacturing a transparent substrate according to claim 7, further comprising:
a step (a) as follows before the step (b),
the step (a): a step of forming a barrier layer containing a tetra- or higher urethane acrylate and having a thickness of 50 to 200 nm on the base material.