Optical member and method of producing the same

Abstract

Provided are an optical member having abrasion resistance and transparency and a method of producing the optical member. The method of producing the optical member includes coating a coating material containing hollow particles and a solvent on a substrate and further coating a coating material containing a binder and a solvent to form a film in which the binder lies between the hollow particles; and then drying the film.

1 . A method of producing an optical member having a substrate and an antireflection film having a layer containing particles and a binder, provided on the substrate,
 the method comprising forming the layer including:
 performing coating with a liquid having particles dispersed in a dispersion medium, and 
 then performing coating with a solution consisting essentially of a component forming the binder, and a solvent, 
   wherein shapes of the particles appear on a surface of the layer on a side opposite to the substrate.   
     
     
         2 . The method of producing an optical member according to  claim 1 , wherein the layer includes the particles at a two-dimensional density of 0.8 or more and 0.88 or less. 
     
     
         3 . The method of producing an optical member according to  claim 1 , wherein the liquid contains no component forming the binder. 
     
     
         4 . The method of producing an optical member according to  claim 1 , wherein the component forming the binder is an alkoxysilane hydrolysis-condensation product. 
     
     
         5 . The method of producing an optical member according to claim  1 , wherein the coating with the liquid and the coating with the solution are performed by spin coating. 
     
     
         6 . The method of producing an optical member according to  claim 1 , wherein the dispersion medium contains any one of 1-methoxy-2-propanol, methyl cellosolve, ethyl cellosolve, and butyl cellosolve. 
     
     
         7 . The method of producing an optical member according to  claim 1 , wherein the particles are hollow particles containing silica. 
     
     
         8 . The method of producing an optical member according to  claim 1 , wherein the coating with the liquid having the particles dispersed in the dispersion medium is performed on a monolayer or multilayer provided on the substrate. 
     
     
         9 . The method of producing an optical member according to  claim 1 , wherein on the surface of the layer on the side opposite to the substrate, a part of surfaces of the particles exposes from the binder. 
     
     
         10 . A method of producing an optical member having a substrate, and an antireflection film having a layer containing particles and a binder, provided on the substrate,
 the method comprising forming the layer including:
 performing coating with a liquid having particles dispersed in a dispersion medium, and 
 then performing coating with a solution consisting essentially of a component forming the binder, and a solvent, 
   wherein a surface of the layer on a side opposite to the substrate has convex portions, and   a shape of the convex portions corresponds to a shape of the particles.   
     
     
         11 . The method of producing an optical member according to  claim 10 , wherein the layer includes the particles at a two-dimensional density of 0.8 or more and 0.88 or less. 
     
     
         12 . The method of producing an optical member according to  claim 10 , wherein on the surface of the layer on the side opposite to the substrate, a part of surfaces of the particles exposes from the binder. 
     
     
         13 . An optical member comprising:
 a substrate; and   an antireflection film having a layer containing particles and a binder, provided on the substrate,   wherein shapes of the particles appear on a surface of the layer on a side opposite to the substrate, and   the layer includes the particles at a two-dimensional density of 0.8 or more and 0.88 or less.   
     
     
         14 . The optical member according to  claim 13 ,
 wherein the binder has a void, and   a volume ratio of the void to the layer is 5 vol % or more and 25 vol % or less.   
     
     
         15 . The optical member according to  claim 13 , wherein the particles are hollow particles containing silica. 
     
     
         16 . The optical member according to  claim 13 , wherein the antireflection film consists of the layer and a monolayer or multilayer provided between the substrate and the layer. 
     
     
         17 . The optical member according to  claim 13 , wherein a monolayer or multilayer having water repellency or oil repellency is provided on the antireflection film. 
     
     
         18 . The optical member according to  claim 15 ,
 wherein the layer contains 15 wt % or more and 50 wt % or less of the binder, and   the layer contains 50 wt % or more and 85 wt % or less of the hollow particles.   
     
     
         19 . The optical member according to  claim 13 ,
 wherein the particles are hollow particles,   the hollow particles have an average particle diameter of 15 nm or more and 100 nm or less,   the layer contains 15 wt % or more and 50 wt % or less of the binder,   the layer contains 50 wt % or more and 85 wt % or less of the hollow particles, and   a refractive index of the antireflection film is 1.23 or more and 1.27 or less.   
     
     
         20 . An optical member comprising:
 a substrate; and   an antireflection film having a layer containing particles and a binder, provided on the substrate,   wherein a surface of the layer on a side opposite to the substrate has convex portions,   a shape of the convex portions corresponds to a shape of the particles, and   the layer includes the particles at a two-dimensional density of 0.8 or more and 0.88 or less.