Patent Application
20090022954
1. Field of the Invention
The present invention relates to a production method for a film having fine irregularities on a surface, and more specifically to an antireflection film having fine irregularities on a surface and to an optical member using the same.
To be specific, the present invention relates to a film and a transparent antireflection film each having fine irregularities mainly composed of alumina on a surface of a transparent thin film layer containing at least one component selected from the group consisting of zirconia, silica, titania, and zinc oxide. Further, the present invention relates to optical members using the film and the transparent antireflection film including: various displays such as a word processor display, a computer display, a TV display, and a plasma display panel; polarizing plates used for liquid crystal display devices; and sunglass lenses, prescription glass lenses, finder lenses for cameras, prisms, fly-eye lenses, toric lenses, and the like, all made of transparent plastics. Further, the present invention relates to optical members including: various optical lenses employing the aforementioned optical members for an image pickup optical system, an observation optical system such as binoculars, a projection optical system used for a liquid crystal projector or the like, and a scanning optical system used for a laser beam printer or the like; covers for various measuring instruments; and windows of cars, trains, and the like.
2. Related Background Art
Numerous films each having fine irregularities on a surface are proposed. Of those, many films are proposed for applications as antireflection materials. For example, there is proposed an antireflection film composed of a polyurethane resin layer having fine irregularities on a surface and an amorphous fluorine-containing polymer provided on the fine irregular surface, as an antireflection film having a fine irregular structure formed on a surface through transfer using a mold having a fine irregular structure (see Japanese Patent Application Laid-Open No. 2001-091706, for example).
Further, there is proposed an antireflection film having a fine irregular surface with a height of 0.01 μm to 0.1 μm, which is a coating film formed using a dispersion liquid containing silicon alkoxide and silicon dioxide fine powder, as an antireflection film having a fine irregular structure formed on a surface through dispersion of fine particles in the film (see Japanese Patent Application Laid-Open No. H09-249411, for example). Those techniques have problems in transparency due to light diffraction and scattering caused by a large lateral size of the fine irregular structure, or a problem of a small antireflection effect due to a longitudinal size thereof being too small, in contrast. Further, a single film component may cause undesirable reflection at an interface between a film and a base material with poor matching in refractive indexes of the film and the base material, and a large antireflection effect may not be expected for an arbitrary base material.
As an example of a method of forming a thin film having fine irregularities on a surface, a sol-gel method is known for forming a transparent thin film having a flower-like alumina fine irregular structure (see “Journal of American Ceramic Society”, 1997, 80(4), 1040-1042; “Chemistry Letters”, 2000, 864; Japanese Patent Application Laid-Open No. H09-202649; and Japanese Patent Application Laid-Open No. 2001-017907, for example). There is disclosed a transparent thin film having a flower-like alumina fine irregular structure prepared by: forming a thin film using an application solution of aluminum butoxide stabilized with ethyl acetoacetate; subjecting the thin film to heat treatment at 400° C.; and immersing the thin film in boiling water (see “Journal of American Ceramic Society”, 1997, 80(4), 1040-1042; and Japanese Patent Application Laid-Open No. H09-202649, for example). Further, there is disclosed a flower-like alumina fine irregular structure prepared by forming a film and immersing the film in warm water without subjecting the film to particular heat treatment (see “Chemistry Letters”, 2000, 864; and Japanese Patent Application Laid-Open No. 2001-017907, for example).
In the transparent thin film having a flower-like alumina fine irregular structure prepared through a sol-gel method, a size of the surface fine irregular structure can be controlled by changing a warm water treatment temperature and a warm water treatment time period. However, the aforementioned alumina single component film has limitations in the surface structure and the size thereof. For example, Japanese Patent Application Laid-Open No. H09-202649 discloses a flower-like transparent alumina film having such a feature that an average surface roughness thereof is 17 nm or more. However, an actual maximum surface roughness is about 30 nm, and no film having a surface roughness of 30 nm or more is obtained. The thin film composed of the alumina single component and having a fine irregular structure has a narrow range for controlling the size of the surface fine irregular structure. Further, the single film component may cause undesirable reflection at an interface between the film and a base material with poor matching in refractive indexes of the film and the base material, and a larger antireflection effect may not be expected for an arbitrary base material.
Further, there is disclosed a method of obtaining an anti-fogging coating film by immersing a film of silica and alumina composite oxide in hot water under heating (see Japanese Patent Application Laid-Open No. H1-114543, for example). Here, the film is prepared by using ethyl silicate as a starting material for silica and an alumina fine particle dispersion sol as a raw material for alumina. The thus-obtained film has high haze and poor transparency with a surface roughness exceeding about 20 nm, and desirably has a surface roughness of about 20 nm or less. The film has problems of insufficient antireflection performance due to a small size of the surface irregular structure. Further, undesirable reflection may occur at an interface between the film and a base material, and thus antireflection performance may degrade.
As described above, the conventional techniques each hardly provide a sufficient range for controlling the size of irregularities of a film having a fine irregular structure on the surface, and hardly develop sufficient antireflection performance.
The present invention has been made in view of the conventional problems, and an object of the present invention is therefore to provide a film in which a fine irregular structure on a surface can be controlled in a wide range, and a production method for the same. Another object of the present invention is to provide a transparent antireflection film which can be applied to an arbitrary transparent base material and shows an excellent antireflection effect for visible light by reducing reflection at an interface between the base material and the irregularities, and to provide an optical member using the same.
The present invention can be specified by the following items described below.
That is, the present invention relates to a film including fine irregularities mainly composed of alumina, and a thin film layer supporting the fine irregularities, in which the thin film layer contains at least one selected from the group consisting of zirconia, silica, titania, and zinc oxide.
The present invention relates to a film, in which the fine irregularities mainly composed of alumina have a height of 0.005 μm to 5.0 μm.
The present invention relates to a film, in which: an average surface roughness Ra′ (obtained by extending a center line average roughness areally) of the film having the fine irregularities mainly composed of alumina is 5 nm or more; and a surface area ratio Sr=S/S0 of the film is 1.1 or more (where, S0 represents an area of an ideally flat measuring surface, and S represents a surface area of an actual measuring surface).
The present invention relates to a film, in which a content of at least one selected from the group consisting of zirconia, silica, titania, and zinc oxide in the thin film layer is 0.001 or more and less than 1.0 in weight ratio with respect to a weight of the film.
The present invention relates to a production method for the aforementioned film, including: forming a multicomponent film using an application liquid containing at least one compound selected from the group consisting of a zirconium compound, a silicon compound, a titanium compound, and a zinc compound, and at least an aluminum compound; and subjecting the multicomponent film to warm water treatment.
The present invention relates to a transparent antireflection film, including fine irregularities mainly composed of alumina, and a transparent thin film layer supporting the fine irregularities, in which the transparent thin film layer contains at least one selected from the group consisting of zirconia, silica, titania, and zinc oxide.
The present invention relates to a transparent antireflection film, in which the fine irregularities mainly composed of alumina have a height of 0.005 μm to 5.0 μm.
The present invention relates to a transparent antireflection film, in which: an average surface roughness Ra′ (obtained by extending a center line average roughness areally) of the film having the fine irregularities mainly composed of alumina is 5 nm or more; and a surface area ratio Sr=S/S0 of the film is 1.1 or more (where, S0 represents an area of an ideally flat measuring surface, and S represents a surface area of an actual measuring surface).
The present invention relates to a transparent antireflection film, in which a content of at least one selected from the group consisting of zirconia, silica, titania, and zinc oxide in the transparent thin film layer is 0.001 or more and less than 1.0 in weight ratio with respect to a weight of the film.
The present invention relates to a production method for the aforementioned transparent antireflection film, including: forming a multicomponent film using an application liquid containing at least one compound selected from the group consisting of a zirconium compound, a silicon compound, a titanium compound, and a zinc compound, and at least an aluminum compound; and subjecting the multicomponent film to warm water treatment.
The present invention relates to an optical member including the aforementioned transparent antireflection film. For example, the optical member is produced by providing the aforementioned transparent antireflection film on a base material. The present invention relates to an image pickup, observation, projection, or scanning optical system having the aforementioned optical member.
A film structure of the present invention includes fine irregularities mainly composed of alumina on a surface of a transparent thin film layer containing at least one component selected from the group consisting of zirconia, silica, titania, and zinc oxide. Further, a content of the component of the transparent thin film layer can be controlled. Thus, the transparent thin film layer may have a refractive index between those of the fine irregularities and the base material. The refractive index between the fine irregular structure and the base material may be continuously varied, and reflection at an interface between the fine irregular structure and the base material may be reduced to minimum. Further, the size of the fine irregularities can be controlled in a wide range to effectively reduce reflection at an interface between the film and air. The optical member of the present invention can attain a significant effect exceeding those of the conventional techniques.
The film and the transparent antireflection film of the present invention each have fine irregularities mainly composed of alumina on a surface of a transparent thin film layer containing at least one component selected from the group consisting of zirconia, silica, titania, and zinc oxide, in which a height of the fine irregularities is 0.005 μm to 5.0 μm, an average surface roughness Ra′ is 5 nm or more, and a surface area ratio Sr is 1.1 or more. In the present invention, at least component selected from the group consisting of alumina, zirconia, silica, titania, and zinc oxide is formed into a composite, to thereby provide a wide range for controlling the fine irregular structure compared with that of an alumina single component thin film having a surface fine irregular structure.
Further, the optical member of the present invention is produced by providing a transparent antireflection film on a base material. To be specific, the optical member of the present invention is produced by providing a transparent thin film layer containing at least one component selected from the group consisting of zirconia, silica, titania, and zinc oxide between the base material and the fine irregularities. Further, the content of the component in the transparent thin film layer can be controlled. Thus, the transparent thin film layer may have a refractive index between those of the fine irregularities and the base material, and the refractive index between the fine irregular structure and the base material may be continuously varied.
As described above, the film and the transparent antireflection film of the present invention each show an excellent antireflection effect for visible light of low reflectance over wide spectrum for use on any base material. Further, the film and the transparent antireflection film of the present invention are each entirely composed of inorganic components, and the whole production process may be performed at 100° C. or less. Thus, the film and the transparent antireflection film each have excellent heat resistance and may be applied to a base material having poor heat resistance such as an organic polymer. As described above, the film and the transparent antireflection film of the present invention each show an excellent antireflection effect for visible light and can provide a transparent antireflection film and an optical member of excellent productivity, respectively.
A film and a transparent antireflection film of the present invention each have fine irregularities mainly composed of alumina and a thin film layer supporting the fine irregularities.
Further, an optical member of the present invention is produced by providing the aforementioned film and transparent antireflection film on a base material, and the thin film layer is provided on a surface of the base material.
The thin film layer of the film of the present invention contains at least one selected from the group consisting of zirconia, silica, titania, and zinc oxide, and develops an effect of suppressing light scattering at an interface between the film and the base material. To be specific, a transparent thin film layer, which provides a refractive index between the refractive index of the fine irregularities and the refractive index of the base material by controlling a content of the component in the transparent thin film layer, is selected. Further, fine irregularities mainly composed of alumina may be formed on the surface of the thin film layer, to thereby reduce light scattering at an interface between the film and air.
The fine irregularities mainly composed of alumina are formed of plate crystals mainly composed aluminum oxide, aluminum hydroxide, or hydrates thereof. An example of particularly preferable crystals is boehmite. A plate structure of the plate crystals is preferably arranged selectively in a vertical direction to the surface of the thin film layer.
A height of the fine irregularities is preferably 0.005 μm to 5.0 μm, more preferably 0.01 μm to 2.0 μm. The term “height of surface irregularities” as used herein refers to a difference in elevation between a top of a convex portion and a bottom of a concave portion formed on a coating film surface. That is, a height of surface irregularities of a coating film of 0.005 μm to 5.0 μm refers to a difference in elevation between a peak and a valley bottom defined in “definition and representation of surface roughness” of JIS B 0601, which corresponds to a maximum surface roughness (Rmax). A height of irregularities of 0.005 μm to 5.0 μm provides effective antireflection performance of the fine irregular structure, prevents degradation of mechanical strength of the irregularities, and results in advantageous production cost of the fine irregular structure.
A surface density of the fine irregularities of the present invention is also important. An average surface roughness Ra′ corresponding to the surface density and obtained by extending a center line average roughness areally is 5 nm or more, more preferably 10 nm or more, furthermore preferably 15 nm or more and 100 nm or less. A surface area ratio Sr is 1.1 or more, more preferably 1.15 or more, and furthermore preferably 1.2 or more and 5.0 and less.
An example of a method of evaluating the thus-obtained fine irregular structure includes observation of the fine irregular structure surface by a scanning probe microscope. An average surface roughness Ra′ obtained by extending a center line average roughness Ra of the film areally and a surface area ratio Sr can be determined through the observation. That is, the average surface roughness Ra′ (nm) is a value obtained by applying the center line average roughness Ra defined by JIS B 0601 to a measuring surface and extending three-dimensionally. The average surface roughness Ra′ is expressed as “an average value of absolute values of deviation from a reference surface to a specified surface”, and is represented by the following equation.
Ra′: average surface roughness (nm)
S0: area of ideally flat measuring surface,
|XR−XL|×|YT−TB|
F(X, Y): height at point of measurement (X, Y), X represents X-axis, Y represents Y-axis
XL to XR: range of X-axis on measuring surface
YB to YT: range of Y-axis on measuring surface
Z0: average height within measuring surface
The surface area ratio Sr is obtained by Sr=S/S0 (S0 represents an area of an ideally flat measuring surface, and S represents a surface area of an actual measuring surface). The surface area of the actual measuring surface is determined as follows. First, the measuring surface is divided into very small triangles consisting of three closest points of data (A, B, C). Then, an area ΔS of each small triangle is determined by using a vector product: [ΔS(ΔABC)]2=[S(S−AB)(S−BC)(S−CA)] (where, AB, BC, and CA are each a length of each side, and 2S=AB+BC+CA). A sum of ΔS's provides the surface area S.
The film having Ra′ of 5 nm or more and Sr of 1.1 or more prevents degradation of antireflection performance for the aforementioned reasons.
The film and the antireflection film of the present invention can be formed through a known vapor phase deposition such as CVD or PVD and a known liquid phase process such as a sol-gel method. A transparent layer may be formed through such techniques in advance, and then plate crystals mainly composed of alumina may be provided. Alternatively, at least one oxide layer containing alumina and any one of zirconia, silica, titania, and zinc oxide may be formed, and then plate crystals of alumina may be provided by selectively dissolving the surface of the layer or precipitating the plate crystals thereon. Of those, a preferable method of growing alumina plate crystals involves: forming a gel film by applying a sol-gel coating liquid containing alumina; and subjecting the gel film to warm water treatment.
At least one compound selected from the group consisting of a zirconium compound, a silicon compound, a titanium compound, and a zinc compound, and an aluminum compound are used as raw materials for the gel film. Corresponding metal alkoxides or salt compounds such as chlorides and nitrates can be used as raw materials for zirconia, silica, titania, zinc oxide, and alumina. Corresponding metal alkoxides are particularly preferably used as raw materials for zirconia, silica, and titania from the viewpoint of film forming properties.
Specific examples of zirconium alkoxide include zirconium tetramethoxide, zirconium tetraethoxide, zirconium tetra-n-propoxide, zirconium tetraisopropoxide, zirconium tetra-n-butoxide, and zirconium tetra-t-butoxide.
Examples of silicon alkoxide include various compounds represented by the general formula Si(OR)4, where each R represents the same or different lower alkyl group such as a methyl group, an ethyl group, a propyl group, an isopropyl group, a butyl group, or an isobutyl group.
Examples of titanium alkoxide include tetramethoxytitanium, tetraethoxytitanium, tetra-n-propoxytitanium, teraisopropoxytitanium, tetra-n-butoxytitanium, and tetraisobutoxytitanium.
Examples of the zinc compound include zinc acetate, zinc chloride, zinc nitrate, zinc stearate, zinc oleate, and zinc salicylate. Particularly preferable examples thereof include zinc acetate and zinc chloride.
Examples of the aluminum compound include aluminum ethoxide, aluminum isopropoxide, aluminum n-butoxide, aluminum sec-butoxide, aluminum tert-butoxide, aluminum acetylacetonate, oligomers thereof, aluminum nitrate, aluminum chloride, aluminum acetate, aluminum phosphate, aluminum sulfate, and aluminum hydroxide.
In the present invention, it is preferable that 0.01 to 15,000 parts by weight, preferably 0.05 to 10,000 parts by weight of the at least one compound selected from the group consisting of a zirconium compound, a silicon compound, a titanium compound, and a zinc compound to the aluminum compound with respect to 100 parts by weight of the aluminum compound. Excellent antireflection performance cannot be expected with a ratio of less than 0.01 part by weight, and fine irregularities may not be formed on a film surface with a ratio exceeding 15,000 parts by weight.
The zirconium, silicon, titanium, zinc, or aluminum compound is dissolved in an organic solvent to prepare a solution of the zirconium, silicon, titanium, zinc, or aluminum compound. An amount of the organic solvent added to the zirconium, silicon, titanium, zinc, or aluminum compound is preferably about 20 in molar ratio with respect to the compound.
In the present invention, the phrase “an amount of A added is about 20 in molar ratio with respect to B” indicates that moles of A added is 20 times moles of B.
Examples of the organic solvent include: alcohols such as methanol, ethanol, 2-propanol, butanol, ethylene glycol, and ethylene glycol mono-n-propyl ether; various aliphatic or alicyclic hydrocarbons such as n-hexane, n-octane, cylohexane, cyclopentane, and cyclooctane; various aromatic hydrocarbons such as toluene, xylene, and ethylbenzene; various esters such as ethyl formate, ethyl acetate, n-butyl acetate, ethylene glycol monomethyl ether acetate, ethylene glycol monoethyl ether acetate, and ethylene glycol monobutyl ether acetate; various ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; various ethers such as dimethoxyethane, tetrahydrofuran, dioxane, and diisopropyl ether; various chlorinated hydrocarbons such as chloroform, methylene chloride, carbon tetrachloride, and tetrachloroethane; and aprotic polar solvents such as N-methyl pyrrolidone, dimethylformamide, dimethylacetamide, and ethylene carbonate. Of the aforementioned various solvents, alcohols are preferably used for preparation of an application solution used in the present invention from the viewpoint of stability of the solution.
Alkoxide raw materials, particularly alkoxides of zirconium, titanium, and aluminum are highly reactive to water and are rapidly hydrolyzed by moisture in air or addition of water, which causes clouding and precipitation of the solution. Further, the zinc compound hardly dissolves in an organic solvent alone or provides an unstable solution.
In order to prevent such problems, a stabilizer is preferably added for stabilization of the solution. Examples of the stabilizer include β-diketone compounds such as acetylacetone, dipivaloylmethane, trifluoroacetylacetone, hexafluoroacetylacetone, benzoylacetone, and benzoylmethane; β-ketoester compounds such as methyl acetoacetate, ethyl acetoacetate, allyl acetoacetate, benzyl acetoacetate, isopropyl acetoacetate, tert-butyl acetoacetate, isobutyl acetoacetate, 2-methoxyethyl acetoacetate, and 3-keto-n-methylvalerate; and alkanolamines such as monoethanolamine, diethanolamine, and triethanolamine. The stabilizer is preferably added in an amount of about 1 in molar ratio with respect to alkoxide.
For example, preparation of an alumina multicomponent application liquid containing silicon alkoxide preferably involves: addition of water or a catalyst to a silicon alkoxide solution in advance for partial hydrolysis of an alkoxyl group; and mixing of the solution containing silicon alkoxide and a solution containing an aluminum compound. Preparation of an alumina multicomponent application liquid containing zirconium alkoxide, titanium alkoxide, or a zinc compound preferably involves: mixing of a solution containing zirconium alkoxide, titanium alkoxide, or a zinc compound and a solution containing an aluminum compound; and addition of water or a catalyst to the mixture.
Examples of the catalyst include nitric acid, hydrochloric acid, sulfuric acid, phosphoric acid, acetic acid, and ammonia.
Further, a water-soluble organic polymer can be added as required. The organic polymer easily elutes from a gel film through immersion of the gel film in warm water, to thereby increase a reaction surface area with the warm water and allow formation of a fine irregular structure at low temperatures and in a short period of time. Further, a type or molecular weight of the organic polymer to be added may be changed to allow control of a shape of the fine irregular structure to be formed. Preferable examples of the organic polymer include polyether glycols such as polyethylene glycol and polypropylene glycol for easy elution thereof from the gel film through immersion of the gel film in warm water. Polyether glycols are preferably added in a range of 0.1 to 10 in weight ratio with respect to the weight of oxides in the film.
In formation of a thin film using an application solution containing no stabilizers, an atmosphere for application is preferably an inert gas atmosphere such as dry air or dry nitrogen. A relative humidity of the dry atmosphere is preferably 30% or less.
Examples of a method of applying a solution for forming a thin film that can be arbitrarily employed include known application means such as a dipping method, a spin coating method, a spray method, a printing method, a flow coating method, and a combination thereof. A film thickness can be controlled by changing a lifting speed in a dipping method, a substrate rotational speed in a spin coating method, and a concentration of the application solution. Of those methods, the lifting speed in the dipping method can be arbitrarily selected depending on a required film thickness, and is preferably a moderate, constant speed of about 0.1 mm/s to 3.0 mm/s after immersion.
The alumina multicomponent gel film prepared through the aforementioned technique only needs to be dried at room temperature for about 30 minutes. Further, the gel film can be dried or subjected to heat treatment at higher temperatures as required. A higher heat treatment temperature can form a more stable irregular structure.
Next, the alumina multicomponent gel film is subjected to immersion treatment in warm water to form alumina fine irregularities. A surface layer of the alumina multicomponent gel film receives a deflocculation action or the like through immersion of the gel film in warm water, and the components of the gel film partially elute. Plate crystals mainly composed of alumina precipitate and grow on the surface layer of the gel film due to a difference in solubilities of various hydroxides in warm water. The warm water preferably has a temperature of 40° C. to 100° C. The warm water treatment time period is about 5 minutes to 24 hours. In such warm water treatment of the alumina multicomponent gel film, crystallization takes place from a difference in solubilities of the respective components in warm water. Thus, the warm water treatment of the alumina multicomponent gel film differs from that of the alumina single component film, and the size of the plate crystals can be controlled in a wide range by changing a composition of inorganic components. As a result, the fine irregularities formed from the plate crystals can be controlled in the aforementioned wide range. The use of zinc oxide as an accessory component allows eutecoid with alumina. The plate crystals may contain a zinc oxide component, to thereby allow control of a refraction index of the fine irregularities formed from the plate crystals and realize excellent antireflection performance.
In the film and the transparent antireflection film of the present invention, a content of zirconia, silica, titania, or zinc oxide in the transparent thin film layer of the film is preferably 0.01 or more and less than 1.0, more preferably 0.005 or more and 0.8 or less in weight ratio with respect to the weight of the film. A content of zirconia, silica, titania, or zinc oxide of 0.001 or more and less than 1.0 in weight ratio changes the size and intercrystalline distance of the plate crystals mainly composed of alumina on the surface, to thereby allow control of the height of the fine irregular structure or the average surface roughness Ra′ within the aforementioned range. A content of zirconia, silica, titania, or zinc oxide may be changed to adjust a refractive index of the film between the refractive index of the base material to be used and the refractive index of the fine irregularities mainly composed of alumina. As a result, the refractive index of the film is consistent with the refractive index of the base material, and reflection at an interface between the film and the base material can be reduced to minimum.
The film and the transparent antireflection film of the present invention each desirably have a film thickness of 0.01 μm to 10 μm, preferably 0.1 μm to 3 μm. The term “film thickness” refers to a thickness of a thin film layer supporting fine irregularities containing the fine irregularities mainly composed of alumina of the present invention.
Examples of the base material used for the optical member of the present invention include glass, a plastic substrate, a glass mirror, and a plastic mirror. Typical examples of the plastic substrate include: films or molded products of thermoplastic resins such as polyester, triacetyl cellulose, cellulose acetate, polyethylene terephthalate, polypropylene, polystyrene, polycarbonate, polymethyl methacrylate, an ABS resin, polyphenylene oxide, polyurethane, polyethylene, and polyvinyl chloride; and crosslinked films or crosslinked products obtained from various thermosetting resins such an unsaturated polyester resin, a phenol resin, crosslinked polyurethane, a crosslinked acrylate resin, and a crosslinked saturated polyester resin. Specific examples of glass include no alkali glass, aluminosilicate glass, and borosilicate glass.
The transparent base material used in the present invention may be any base material which may be finally formed into a shape according to an intended use. A flat plate, a film, a sheet, or the like is used as the transparent base material, and the base material may have a two-dimensional or three-dimensional curved surface. A thickness of the base material may be determined arbitrarily. The base material generally has a thickness of 5 mm or less, but is not limited thereto.
The antireflection film of the present invention may be further provided with a layer for imparting various functions, in addition to the layer described above. For example, the antireflection film may be provided with a hard coat layer for improving a film strength, or an adhesive layer or primer layer for improving adhesion between the transparent base material and the hard coat layer. The refractive index of each of the other layers provided between the transparent base material and the hard coat layer is preferably between the refractive index of the transparent base material film and the refractive index of the hard coat layer.
Hereinafter, the present invention will be described in detail by examples. However, the present invention is not limited thereto.
Transparent films each having fine irregularities on a surface obtained in the following Examples and Comparative Examples were evaluated through the following methods.
Photographic observation (accelerating voltage: 10.0 kV, magnification: 30,000) was conducted on a surface of a surface layer of a coating film using a scanning electron microscope (FE-SEM, S4500, manufactured by Hitachi, Ltd.).
An average surface roughness Ra′ obtained by extending areally a center line average roughness defined by JIS B 0601 and a surface area ratio Sr were determined using a scanning probe microscope (SPM, SPI-3800, DFM mode, manufactured by Seiko Instruments & Electronics Ltd.).
Photographic observation (accelerating voltage: 200 kV, magnification: 41,000×5.0) was conducted on a cross section of the coating film using a high resolution transmission electron microscope (HRTEM, H-9000NAR, manufactured by Hitachi, Ltd.). Then, an EDX analysis (energy resolution: 137 eV, accelerating voltage: 200 kV, beam diameter: about 1 nmΦ) was conducted at an arbitrary position using an elemental analyzer (VOYAGER III M3100, manufactured by NORAN).
An automatic optical element measurement device (ART-25GD, manufactured by JASCO Corporation) was used. A disc glass plate was used. Incident angles of light for transmittance and reflectance measurement were 0° and 100, respectively.
A clear float glass substrate (soda lime silicate-based composition) of a size of 100 mm×100 mm and a thickness of about 2 mm was subjected to ultrasonic cleaning with isopropyl alcohol and was dried, to thereby prepare a glass substrate for coating.
Aluminum sec-butoxide (Al(O-sec-Bu)3) was dissolved in 2-propanol (IPA), and ethyl acetoacetate (EAcAc) was added thereto as a stabilizer. The mixture was stirred at room temperature for about 3 hours, to thereby prepare an Al2O3 sol solution. A molar ratio of the solution was Al(O-sec-Bu)3:IPA:EAcAc=1:20:1.
Meanwhile, zirconium isopropoxide (Zr(O-iso-Pr)4) was also dissolved in IPA, and EAcAc was added thereto. The mixture was stirred at room temperature for about 3 hours, to thereby prepare a ZrO2 sol solution. The molar ratio of the solution was Zr(O-iso-Pr)4:IPA:EAcAc=1:20:1.
The ZrO2 Sol solution was added into the Al2O3 sol solution in a weight ratio of Al2O3:ZrO2=0.7:0.3. The mixture was stirred for about 30 minutes, and 0.01 M of diluted hydrochloric acid (HCl aq.) was added thereto. The whole was stirred at room temperature for about 3 hours, to thereby prepare an Al2O3—ZrO2 sol as an application liquid. An amount of HCl aq. added was a sum of twice moles of Al(O-sec-Bu)3 and twice moles of Zr(O-iso-Pr)4.
Next, the glass substrate for coating was immersed in the application liquid, and then an coating film was formed on a surface of the glass substrate through a dipping method (lifting speed of 3 mm/s, 20° C., 56% R.H.). The resultant was dried and then subjected to heat treatment at 100° C. for 1 hour, to thereby obtain a transparent, amorphous Al2O3/ZrO2-based gel film. Next, the gel film was immersed in hot water at 100° C. for 30 minutes and then dried at 100° C. for 10 minutes.
Scanning electron microscope (FE-SEM) observation and scanning probe microscope (SPM) observation were conducted on the surface of the obtained film.
The FE-SEM image of
The results of the EDX analysis at each position in
The results revealed that an amorphous composite film composed of zirconia and alumina was formed on the glass substrate and that fine irregularities of plate crystals mainly composed of alumina were formed on the film surface layer.
Table 1 shows a relationship between the average surface roughness Ra′ of the thin film and the film transmittance/reflectance. Table 1 further shows the results of the glass substrate alone having no film coated thereon as Reference Example 1.
The Al2O3 sol was prepared in the same manner as that in Example 1.
Meanwhile, tetraethoxysilane (TEOS), IPA, and 0.01 M (HCl aq.) were mixed, and the whole was stirred at room temperature for about 3 hours, to thereby prepare an SiO2 sol solution. A molar ratio of the solution was TEOS:IPA=1:20. An amount of HCl aq. added was a sum of equal moles of Al(O-sec-Bu)3 and twice moles of TEOS. The SiO2 sol solution was added into the Al2O3 sol solution in a weight ratio of Al2O3:SiO2=0.7:0.3, to thereby prepare an Al2O3—SiO2 sol as an application liquid.
Next, the same glass substrate subjected to the same cleaning treatment as that of Example 1 was immersed in the application liquid, and then an coating film was formed on the surface of the glass substrate through a dipping method (lifting speed of 3 mm/s, 20° C., 56% R.H.). The resultant was dried and then subjected to heat treatment at 100° C. for 1 hour, to thereby obtain a transparent, amorphous Al2O3/SiO2-based gel film. Next, the gel film was immersed in hot water at 100° C. for 30 minutes and then dried at 100° C. for 10 minutes.
The FE-SEM observation and SPM observation were conducted on the surface of the obtained film, and fine irregularities of plate crystals, similar to those of Example 1, were observed. The average surface roughness Ra′ (nm) and surface area ratio Sr obtained through the SPM measurement were Ra′=50 nm and Sr=2.5, respectively. The results of the cross-section TEM observation and EDX measurement revealed that an amorphous composite film composed of silica and alumina was formed on the glass substrate, and that fine irregularities of plate crystals mainly composed of alumina were formed on the composite film.
Table 1 shows the relationship between the average surface roughness Ra′ and the film transmittance/reflectance.
The SiO2 sol solution used in Example 2 was added into the Al2O3 sol solution used in Example 1 in a weight ratio of Al2O3 : SiO2=0.5:0.5, to thereby prepare an Al2O3—SiO2 sol as an application liquid.
Next, FE-SEM observation and SPM observation were conducted on the surface of the film formed, subjected to hot water treatment, and dried under the same conditions as those of Example 2, and fine irregularities of plate crystals mainly composed of alumina, similar to those of Example 1, were observed. The average surface roughness Ra′ (nm) and surface area ratio Sr obtained through the SPM measurement were Ra′=75 nm and Sr=2.7, respectively.
Table 1 shows the relationship between the average surface roughness Ra′ and the film transmittance/reflectance.
The Al2O3 sol was prepared in the same manner as that in Example 1.
Meanwhile, titanium n-butoxide (Ti(O-n-Bu)4) was also dissolved in IPA, and EAcAc was added thereto. The mixture was stirred at room temperature for about 3 hours, to thereby prepare a TiO2 sol solution. A molar ratio of the solution was Ti(O-n-Bu)4:IPA EAcAc=1:2:1.
The TiO2 sol solution was added into the Al2O3 sol solution in a weight ratio of Al2O3:TiO2=0.7:0.3. The mixture was stirred for about 30 minutes, and 0.01 M (HCl aq.) was added thereto. The whole was stirred at room temperature for about 3 hours, to thereby prepare an Al2O3—TiO2 sol as an application liquid. An amount of HCl aq. added was a sum of twice moles of Al(O-sec-Bu)3 and twice moles of Ti(O-n-Bu)4.
Next, the same glass substrate subjected to the same cleaning treatment as that in Example 1 was immersed in the application liquid, and then an coating film was formed on a surface of the glass substrate through a dipping method (lifting speed of 3 mm/s, 20° C., 56% R.H.). The resultant was dried and then subjected to heat treatment at 100° C. for 1 hour, to thereby obtain a transparent, amorphous Al2O3/TiO2-based gel film. Next, the gel film was immersed in hot water at 100° C. for 30 minutes and then dried at 100° C. for 10 minutes.
The FE-SEM observation and SPM observation were conducted on the surface of the obtained film, fine irregularities of plate crystals, similar to those of Example 1, were observed. The average surface roughness Ra′ (nm) and surface area ratio Sr obtained through the SPM measurement were Ra′=48 nm and Sr=2.5, respectively. The results of the cross-section TEM observation and EDX measurement revealed that an amorphous composite film composed of titania and alumina was formed on the glass substrate and that plate crystals mainly composed of alumina were formed on the amorphous composite film.
Table 1 shows the relationship between the average surface roughness Ra′ and the film transmittance/reflectance.
The Al2O3 sol was prepared in the same manner as that in Example 1. Meanwhile, zinc acetate dihydrate (Zn(CH3COO)2·2H2O) was also dissolved in (IPA), and monoethanolamine (MEA) was added thereto. The mixture was stirred at room temperature for about 3 hours, to thereby prepare a ZnO solution. A molar ratio of the solution was Zn(CH3COO)2·2H2O:IPA:MEA=1:10:1. The ZnO sol solution was added into the Al2O3 sol solution in a weight ratio of Al2O3:ZnO=0.9:0.1, and the whole was stirred at room temperature for about 3 hours, to thereby prepare an Al2O3—ZnO sol as an application liquid.
Next, the same glass substrate subjected to the same cleaning treatment as that in Example 1 was immersed in the application liquid, and then an coating film was formed on a surface of the glass substrate through a dipping method (lifting speed of 2 mm/s, 20° C., 56% R.H.). The resultant was dried and then subjected to heat treatment at 400° C. for 0.5 hour, to thereby obtain a transparent, amorphous Al2O3/ZnO-based gel film. Next, the gel film was immersed in hot water at 100° C. for 30 minutes and then dried at 100° C. for 10 minutes.
FE-SEM observation and SPM observation were conducted on the surface of the obtained film, and fine irregularities of plate crystals, similar to those of Example 1, were observed. The average surface roughness Ra′ (nm) and surface area ratio Sr obtained through the SPM measurement were Ra′=32 nm and Sr=2.1, respectively. The glass substrate was cut out using a dicing saw in the same manner as that in Example 1 and was then subjected to cross-wise lamination through an FIB method, for composition analysis of fine irregular portions through cross-section TEM observation and EDX measurement.
The cross-section TEM image of
Table 1 shows the relationship between the average surface roughness Ra′ of the thin film and the film transmittance/reflectance.
Al(O-sec-Bu)3 was dissolved in IPA, and EAcAc was added thereto as a stabilizer. The mixture was stirred at room temperature for about 3 hours, and 0.01 M of diluted hydrochloric acid (HCl aq.) was added thereto. The whole was stirred at room temperature for about 3 hours, to thereby prepare an Al2O3 sol solution. A molar ratio of the solution was Al(O-sec-Bu)3 : IPA : EAcAc : HCl aq.=1:20:1:1.
Next, the same glass substrate subjected to the same cleaning treatment as that in Example 1 was immersed in the application liquid, and then an coating film was formed on a surface of the glass substrate through a dipping method (lifting speed of 3 mm/s, 20° C., 56% R.H.). The resultant was dried and then subjected to heat treatment at 100° C. for 1 hour for calcination, to thereby coat a transparent, amorphous Al2O3 film. Next, the film was immersed in hot water at 100° C. for 30 minutes and then dried at 100° C. for 10 minutes.
FE-SEM observation and SPM observation were conducted on the surface of the obtained film, and a random and complicate fine irregular structure was observed. The average surface roughness Ra′ (nm) and surface area ratio Sr obtained through the SPM measurement were Ra′=26 nm and Sr=1.7, respectively.
Table 1 shows the relationship between the average surface roughness Ra′ of the transparent alumina thin film and the film transmittance/reflectance.
Example 6 describes the case of a concave lens. However, the present invention is not limited thereto, and the lens may be a convex lens or a meniscus lens.
Example 7 describes the case of a prism having optical surfaces of 90° and 45°. However, the present invention is not limited thereto, and the prism may have optical surfaces of any angles.
Example 10 of the present invention describes an example of the use of the optical member of the present invention for an observation optical system.
In
Example 11 of the present invention describes an example of the use of the optical member of the present invention for an image pickup optical system.
In
Example 12 of the present invention describes an example of the use of the optical member of the present invention for a projection optical system (projector).
In
The transparent antireflection film 3 of Example 12 is mainly composed of alumina and contains at least one accessory component selected from the group consisting of zirconia, silica, titania, and zinc oxide. Thus, the transparent antireflection film 3 has high heat resistance and may be used at a position of 13a close to the light source 12 and exposed to high heat without possibility of performance degradation.
Example 13 of the present invention describes an example of the use of the optical member of the present invention for a scanning optical system (laser beam printer).
In
The film and the transparent antireflection film of the present invention can be applied to an arbitrary transparent base material, and show an excellent antireflection effect for visible light by reducing reflection at an interface between the base material and the irregularities. Therefore, the film and the transparent antireflection film of the present invention can be used for optical members including: various displays such as a word processor display, a computer display, a TV display, and a plasma display panel; polarizing plates used for liquid crystal display devices; and sunglass lenses, prescription glass lenses, finder lenses for cameras, prisms, fly-eye lenses, toric lenses, and the like, all made of transparent plastics. Further, the film and the transparent antireflection film of the present invention can be used for optical members including: various optical lenses employing the aforementioned optical members for an image pickup optical system, an observation optical system such as binoculars, a projection optical system used for a liquid crystal projector or the like, and a scanning optical system used for a laser beam printer or the like; covers for various measuring instruments; and windows of cars, trains, and the like.
This application claims priorities from Japanese Patent Applications No. 2004-046257 filed Feb. 23, 2004 and No. 2005-006760 filed Jan. 13, 2005, which are hereby incorporated by reference herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2004-046257 | Feb 2004 | JP | national |
| 2005-006760 | Jan 2005 | JP | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11058193 | Feb 2005 | US |
| Child | 12236805 | US |
