Hard coat film

Abstract

A hard coat film excellent in abrasion resistance and saponification resistance. A hard coat layer includes a cured product of a curable resin composition containing a reactive inorganic fine particle having an average particle diameter of 5 nm to 30 nm, and has a skin layer, wherein the reactive inorganic fine particles are localized, in its surface region being an interface and its vicinity on a side opposite to a transparent substrate film side of the hard coat layer. Alternatively, the reactive inorganic fine particle has an average particle diameter of 30 nm to 100 nm, and has density distribution in a thickness direction of the hard coat layer lowest at an interface on a side opposite to a transparent substrate film side of the hard coat layer while the density is highest at an interface and its vicinity on the transparent substrate film side of the hard coat layer.

1 . A hard coat film in which a hard coat layer is provided on a transparent substrate film,
 wherein the hard coat layer comprises a cured product of a curable resin composition for the hard coat layer containing:   a reactive inorganic fine particle (A) having an average particle diameter of 30 nm to 100 nm, and having a reactive functional group (a) introduced by an organic component, which covers at least a part of a surface of the reactive inorganic fine particle (A), on the surface, and   a curable binder system containing a binder component (B) having a reactive functional group (b) cross-linkingly reactive with the reactive functional group (a) of the reactive inorganic fine particle (A), and the curable binder system itself also having curing reactivity; and   wherein the reactive inorganic fine particle (A) has density distribution in a thickness direction of the hard coat layer, in which density of the reactive inorganic fine particle (A) is lowest at an interface on a side opposite to a transparent substrate film side of the hard coat layer while the density of the reactive inorganic fine particle (A) is highest at an interface and its vicinity on the transparent substrate film side of the hard coat layer.   
     
     
         2 . The hard coat film according to  claim 1 , wherein when a thickness-directional cross section of the hard coat layer is defined as P 1  and a vertical-directional density of the reactive inorganic fine particle (A) in the cross section P 1  is de fined as a number (particles/μm 2 ) of the react ive inorganic fine particle (A) per unit area of the cross section P 1 , density of the reactive inorganic fine particle (A) at any part in a region from the interface on the side opposite to the transparent substrate film side to 500 nm in depth of the cross section P 1  is 150 particles/μm 2  or less. 
     
     
         3 . The hard coat film according to  claim 1 , wherein a number of the reactive inorganic fine particle (A) partially projected from the interface on the side opposite to the transparent substrate film side of the hard coat layer is 150 or less per unit area of the interface. 
     
     
         4 . The hard coat film according to  claim 1 , wherein when a planar-directional cross section of the hard coat layer is defined as P 2  and a planar-directional density of the reactive inorganic fine particle (A) in the cross section P 2  is defined as a number (particles/μm 2 ) of the reactive inorganic fine particle (A) per unit area of the cross section P 2 , difference of densities of the reactive inorganic fine particle (A) of two parts in the cross section P 2  at any height of the hard coat layer is 30 particles/μm 2  or less. 
     
     
         5 . The hard coat film according to  claim 1 , wherein hardness of the hard coat layer when a pencil hardness test in accordance with JIS K5600-5-4 (1999) is performed with a load of 500 g is 4H or more. 
     
     
         6 . The hard coat film according to  claim 1 , wherein layer thickness of the hard coat layer is from 1 μm to 100 μm. 
     
     
         7 . The hard coat film according to  claim 1 , wherein the organic component covering the reactive inorganic fine particle (A) is contained in the reactive inorganic fine particles (A) by 1.00×10 −3  g/m 2  or more per unit area of the inorganic fine particle before being covered. 
     
     
         8 . The hard coat film according to  claim 1 , wherein the reactive functional group (a) of the reactive inorganic fine particle (A) and the reactive functional group (b) of the binder component (B) have a polymerizable unsaturated group. 
     
     
         9 . The hard coat film according to  claim 1 , wherein the reactive inorganic fine particles (A) are obtained by dispersing inorganic fine particles in water and/or an organic solvent serving as a dispersion media in the presence of one or more kinds of surface modification compounds having a molecular weight of 500 or less selected from the group consisting of saturated or unsaturated carboxylic acid, acid anhydride, acid chloride, ester and acid amide corresponding to the carboxylic acid, amino acid, imine, nitrile, isonitrile, an epoxy compound, amine, a β-dicarbonyl compound, silane and a metallic compound having a functional group. 
     
     
         10 . The hard coat film according to  claim 9 , wherein the surface modification compound is a compound having a hydrogen bond-forming group. 
     
     
         11 . The hard coat film according to  claim 9 , wherein at least one kind of the surface modification compound has a polymerizable unsaturated group to be the reactive functional group (a). 
     
     
         12 . The hard coat film according to  claim 1 , wherein the reactive inorganic fine particles (A) are obtained by bounding a compound containing the reactive functional group (a) being introduced on the surface of the reactive inorganic fine particle (A), a group represented by the following chemical formula (1), and a silanol group or a group producing the silanol group by hydrolysis, with metal oxide fine particles:
   -Q 1 -C(=Q 2 )-NH—  Chemical formula (1)
   
       wherein Q 1  is NH, O (oxygen atom) or S (sulfur atom); and Q 2  is O or S. 
     
     
         13 . The hard coat film according to  claim 1 , wherein the binder component (B) is a compound having three or more reactive functional groups (b). 
     
     
         14 . The hard coat film according to  claim 1 , wherein a content of the reactive inorganic fine particle (A) is from 10 to 60 wt % with respect to a total solid content. 
     
     
         15 . The hard coat film according to  claim 1 , wherein the transparent substrate film mainly comprises cellulose acylate, a cycloolefin polymer, an acrylate-based polymer or polyester.