CN103360857A - 平坦保护层用组合物及其制备方法和显示装置 - Google Patents

平坦保护层用组合物及其制备方法和显示装置 Download PDF

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CN103360857A
CN103360857A CN2013103023903A CN201310302390A CN103360857A CN 103360857 A CN103360857 A CN 103360857A CN 2013103023903 A CN2013103023903 A CN 2013103023903A CN 201310302390 A CN201310302390 A CN 201310302390A CN 103360857 A CN103360857 A CN 103360857A
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massfraction
protective layer
layer used
smooth protective
used composition
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CN103360857B (zh
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杨同华
黎敏
张继凯
张思凯
冯贺
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BOE Technology Group Co Ltd
Beijing BOE Display Technology Co Ltd
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Beijing BOE Display Technology Co Ltd
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Abstract

本发明涉及显示技术领域,特别是涉及一种平坦保护层用组合物及其制备方法和一种显示装置。所述平坦保护层用组合物,包括质量分数为1%~10%的微胶囊,所述微胶囊囊壁包括碱不溶性树脂,所述微胶囊囊芯包括:质量分数为30%~60%的可进行光固化的不饱和树脂低聚物;质量分数为30%~60%的光聚合单体;质量分数为1%~10%的光敏剂;质量分数为0%~5%的添加剂。采用本发明的技术方案,可以实现平坦保护层破损处的修补,大大提高产品的良率。

Description

平坦保护层用组合物及其制备方法和显示装置
技术领域
本发明涉及显示技术领域,特别是涉及一种平坦保护层用组合物及其制备方法和一种显示装置。
背景技术
在平板显示装置中,薄膜晶体管液晶显示器(Thin Film Transistor LiquidCrystal Display,简称TFT-LCD)具有体积小、功耗低、制造成本相对较低和无辐射等特点,在当前的平板显示器市场占据了主导地位。
目前,TFT-LCD的主要结构包括对盒在一起的阵列基板和彩膜基板(CF)。其中,彩膜基板主要包括:玻璃基板、黑矩阵(Black Matrix,简称BM)、彩色光阻和平坦保护(Overcoat,简称OC)层。一般而言,黑矩阵以格栅、条纹或斑纹形式排列在彩色光阻形成的彩色图案之间,黑矩阵的主要作用是通过抑制颜色间的混合来提高画面对比度,也可以遮挡杂散光,防止像素间漏光引起的TFT工作失常。彩色光阻包括红(Red)、绿(Green)、蓝(Blue)着色层,为了保证彩膜基板的色彩均匀性与防止漏光,RGB彩色光阻与BM之间存在一定宽度的搭接,通常这个宽度在3微米以上;且搭接区域的RGB彩色光阻的高度较其他区域偏高,从而产生较大的角段差;为了消除此角段差,需要在RGB表面涂覆一层OC材料以保证CF的表面平坦性,从而保证取向层(PI)摩擦(rubbing)的均匀性来实现高画面品质;此外,OC层还可以作为保护层以防止着色层中的小分子物质迁移至液晶层,污染液晶造成色度不均;因此,OC层表面平整度与完整度对于提升TFT-LCD产品品质至关重要。为避免OC层不良,现有工艺需要在平坦保护层制备完成后进行修补(repair)工序,该工序可以通过研磨修补对OC层进行修复,但对OC层破损引起的缺陷还未有有效的修补手段。
发明内容
本发明的目的是提供一种平坦保护层用组合物及其制备方法和一种显示装置,用以实现平坦保护层破损处的修补,大大提高产品的良率。
本发明平坦保护层用组合物,包括:质量分数为1%~5%的微胶囊,所述微胶囊囊壁包括碱不溶性树脂,所述微胶囊囊芯包括:
质量分数为30%~60%的可进行光固化的不饱和树脂低聚物;
质量分数为30%~60%的光聚合单体;
质量分数为1%~10%的光敏剂;
质量分数为0%~5%的添加剂。
优选的,所述可进行光固化的不饱和树脂低聚物包括环氧丙烯酸树脂、聚酯丙烯酸树脂、聚氨酯丙烯酸酯中的一种或几种;所述光聚合单体包括二季戊四醇六丙烯酸酯(DPHA)、三羟甲基丙烷三丙烯酸酯(TMPTA)、季戊四醇四丙烯酸酯(PETA)、二季戊四醇五丙烯酸酯(DPPA)中的一种或几种;所述光敏剂包括苯偶姻类化合物,如安息香、安息香双甲醚;苯偶酰类化合物,如二苯基乙酮;烷基苯酮类化合物,如α-羟烷基苯酮;酰基磷氧化物,如芳酰基膦氧化物、双苯甲酰基苯基氧化膦;二苯甲酮类,如二苯甲酮、2,4-二羟基二苯甲酮;硫杂蒽酮类化合物,如硫代丙氧基硫杂蒽酮、异丙基硫杂蒽酮中的一种或几种。
优选的,所述的平坦保护层用组合物,还包括:
质量分数为1%~20%的含环氧基团的丙烯酸酯树脂;
质量分数为1%~20%的固化剂;
质量分数为70.5%~83.5%的有机溶剂;
质量分数为0.01%~2%的助剂。
较佳的,所述含环氧基团的丙烯酸酯树脂包括丙烯酸甲酯改性环氧树脂、甲基丙烯酸甲酯改性环氧树脂、丙烯酸乙酯改性环氧树脂、甲基丙烯酸乙酯改性环氧树脂、丙烯酸丁酯改性环氧树脂、甲基丙烯酸丁酯改性环氧树脂、丙烯酸酯共聚物改性环氧树脂或甲基丙烯酸酯共聚物改性环氧树脂中的一种或多种;所述固化剂包括有机酸、酸酐、脂肪胺、芳香胺、酰胺中的一种或多种,具体可以为马来酸酐、邻苯二甲酸酐、偏苯三甲酸酐、聚酰胺树脂中的一种或多种;所述有机溶剂包括醇、酯、酮、醚中的一种或多种,具体可以为丙二醇单甲醚醋酸酯、3-乙氧基丙酸乙酯中的一种或多种。
优选的,所述碱不溶性树脂包括环氧树脂或聚氨酯树脂,具体可以为江苏三木生产的环氧丙烯酸树脂6118、聚酯丙烯酸树脂SK8924或聚氨酯丙烯酸酯SM6201。
优选的,所述添加剂和所述助剂分别为附着力促进剂和流平剂中的一种或多种,附着力促进剂具体可以为γ-(2,3-环氧丙氧)丙基三甲氧基硅烷(KH-560,购自山东铭扬化工有限公司)或γ-甲基丙烯酰氧基丙基三甲基硅烷(KH-570,购自山东铭扬化工有限公司),流平剂可以为荷兰埃夫卡公司的EFKA-3883。
本发明显示装置,包括彩膜基板,所述彩膜基板中的平坦保护层采用上述任一种所述的平坦保护层用组合物得到。
本发明平坦保护层用组合物的制备方法,包括:
将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合后进行分散,制得微胶囊囊芯用组合物;
将所述微胶囊囊芯用组合物滴加于微胶囊囊壁的溶液中,形成微胶囊;
取质量分数为1%~5%的微胶囊与平坦保护层用组合物的组分混合,形成平坦保护层用组合物。所述平坦保护层用组合物的组分可以为本发明平坦保护层用组合物不包括微胶囊的其他组分,也可以为现有技术中平坦保护层用组合物的各组分。
优选的,平坦保护层用组合物的组分包括质量分数为1%~20%的含环氧基团的丙烯酸酯树脂;质量分数为1%~20%的固化剂;质量分数为70.5%~83.5%的有机溶剂;质量分数为0.01%~2%的助剂。
优选的,所述将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合后进行分散具体为:
将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合形成混合物;
将所述混合物在搅拌下分散1~4小时,所述搅拌的转速为300~1000转/分。
在本发明平坦保护层用组合物中,由于在平坦保护层中引入微胶囊,其结构包含微胶囊囊壁和微胶囊囊芯,由于囊壁的保护作用,囊芯物质正常情况下不会流出;相反,在OC层制备过程中,由于污染颗粒的存在或外力的划伤,会造成OC膜层出现破损,该破损引起的剪切力迫使微胶囊囊壁破损,使得内部囊芯中的组合物流出,填充满破损处,经过一曝光处理,即可完成对破损的修补,而无需等待专门的修复工艺,且可大大提升TFT-LCD的产品良率与产品品质。
具体实施方式
为了解决现有技术中存在的平坦保护层的破损未能修补导致产品缺陷的技术问题,本发明提供了一种平坦保护层用组合物及其制备方法和一种显示装置。在该技术方案中,由于在组合物中增加了微胶囊,微胶囊包括囊壁和囊芯,囊壁在破损剪切力的作用下会破裂,从而囊芯物质流出,囊芯中包括平坦保护层用的树脂低聚物及光聚合单体,在紫外光照射下可实现对破损的修补,从而保持平坦保护层的完整性和平坦性,进而提高产品的良率。为使本发明的目的、技术方案和优点更加清楚,以下举实施例对本发明作进一步详细说明。
本发明平坦保护层用组合物,包括质量分数为1%~10%的微胶囊,所述微胶囊囊壁包括碱不溶性树脂,所述微胶囊囊芯包括:
质量分数为30%~60%的可进行光固化的不饱和树脂低聚物;
质量分数为30%~60%的光聚合单体;
质量分数为1%~10%的光敏剂;
质量分数为0%~5%的添加剂。
在本发明实施例中,在平坦保护层用组合物中增加了微胶囊,微胶囊的囊芯包括不饱和树脂低聚物、光聚合单体、光敏剂和添加剂,囊壁在破损剪切力的作用下会破裂,从而囊芯物质流出,囊芯中包括平坦保护层用的树脂低聚物及光聚合单体,在紫外光照射下可实现对破损的修补,从而保持平坦保护层的完整性和平坦性,进而提高产品的良率。由于在平坦保护层用组合物中添加了微胶囊,可以节约后续的对平坦保护层的修补工艺,节约了产品的生产时间,提高了产品的生产效率。
优选的,所述可进行光固化的不饱和树脂低聚物包括环氧丙烯酸树脂、聚酯丙烯酸树脂、聚氨酯丙烯酸酯中的一种或几种;所述光聚合单体包括二季戊四醇六丙烯酸酯(DPHA)、三羟甲基丙烷三丙烯酸酯(TMPTA)、季戊四醇四丙烯酸酯(PETA)、二季戊四醇五丙烯酸酯(DPPA)中的一种或几种;所述光敏剂包括苯偶姻类化合物,如安息香、安息香双甲醚;苯偶酰类化合物,如二苯基乙酮;烷基苯酮类化合物,如α-羟烷基苯酮;酰基磷氧化物,如芳酰基膦氧化物、双苯甲酰基苯基氧化膦;二苯甲酮类,如二苯甲酮、2,4-二羟基二苯甲酮;硫杂蒽酮类化合物,如硫代丙氧基硫杂蒽酮、异丙基硫杂蒽酮中的一种或几种,本发明优选的光敏剂2-羟基-2-甲基-1-苯基丙酮、2-甲基-2-(4-吗啉基)-1-[4-(甲硫基)苯基]-1-丙酮、2-羟基-2-甲基-1-苯基丙酮、1-羟基环己基苯基甲酮或2-羟基-2-甲基-1-苯基丙酮。
优选的,所述的平坦保护层用组合物,还包括:
质量分数为1%~20%的含环氧基团的丙烯酸酯树脂;
质量分数为1%~20%的固化剂;
质量分数为70.5%~83.5%的有机溶剂;
质量分数为0.01%~2%的助剂。
优选的,所述含环氧基团的丙烯酸酯树脂包括丙烯酸甲酯改性环氧树脂、甲基丙烯酸甲酯改性环氧树脂、丙烯酸乙酯改性环氧树脂、甲基丙烯酸乙酯改性环氧树脂、丙烯酸丁酯改性环氧树脂、甲基丙烯酸丁酯改性环氧树脂、丙烯酸酯共聚物改性环氧树脂或甲基丙烯酸酯共聚物改性环氧树脂中的一种或多种;所述固化剂包括有机酸、酸酐、脂肪胺、芳香胺、酰胺中的一种或多种,具体可以为马来酸酐、邻苯二甲酸酐、偏苯三甲酸酐、聚酰胺树脂中的一种或多种;所述有机溶剂包括醇、酯、酮、醚中的一种或多种,具体可以为丙二醇单甲醚醋酸酯、3-乙氧基丙酸乙酯中的一种或多种。
优选的,所述碱不溶性树脂包括环氧树脂或聚氨酯树脂,具体可以为江苏三木生产的环氧丙烯酸树脂6118、聚酯丙烯酸树脂SK8924或聚氨酯丙烯酸酯SM6201。
优选的,所述添加剂和所述助剂分别为附着力促进剂和流平剂中的一种或多种,附着力促进剂具体可以为γ-(2,3-环氧丙氧)丙基三甲氧基硅烷(KH-560,购自山东铭扬化工有限公司)或γ-甲基丙烯酰氧基丙基三甲基硅烷(KH-570,购自山东铭扬化工有限公司),流平剂可以为荷兰埃夫卡公司的EFKA-3883。
本发明实施例还提供一种显示装置,包括彩膜基板,所述彩膜基板中的平坦保护层采用上述任一种平坦保护层用组合物得到。除平坦保护层外,显示装置的其他结构与现有工艺一致。所述显示装置可以为:液晶面板、电子纸、OLED面板、液晶电视、液晶显示器、数码相框、手机、平板电脑等具有任何显示功能的产品或部件。
本发明实施例提供一种平坦保护层用组合物的制备方法,包括:
将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合后进行分散,制得微胶囊囊芯用组合物;
将所述微胶囊囊芯用组合物滴加于微胶囊囊壁的溶液中,形成微胶囊;
取质量分数为1%~10%的微胶囊与平坦保护层用组合物的组分混合,形成平坦保护层用组合物。所述平坦保护层用组合物的组分可以为本发明平坦保护层用组合物不包括微胶囊的其他组分,也可以为现有技术中平坦保护层用组合物的各组分。
优选的,平坦保护层用组合物的组分包括质量分数为1%~20%的含环氧基团的丙烯酸酯树脂;质量分数为1%~20%的固化剂;质量分数为70.5%~83.5%的有机溶剂;质量分数为0.01%~2%的助剂。
优选的,所述将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合后进行分散具体为:
将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合形成混合物;
将所述混合物在搅拌下分散1~4小时,所述搅拌的转速为300~1000转/分。
以下列举具体的实施例对本发明平坦保护层用组合物及其制备方法做进一步解释,但本发明并不限于以下实施例。
一、微胶囊囊芯用组合物的制备方法
实施例1~5是制备微胶囊囊芯用组合物的实施例。将表1实施例1~5中质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合形成混合物;
将所述混合物在搅拌下分散1~4小时,所述搅拌的转速为300~1000转/分,优选在搅拌转速600转/分条件下分散2小时,制得微胶囊囊芯用组合物,所述搅拌可以采用机械搅拌的方式。
表1微胶囊囊芯实施例1~5组分及其质量分数表
二、微胶囊的制备方法
实施例6~9是制备微胶囊的实施例。将上述制得的微胶囊囊芯组合物,滴加于用于形成微胶囊囊壁的树脂溶液中,如采用环氧树脂或聚氨酯树脂的二甲苯溶液,各组分及其质量分数如表2所示,由于囊芯和囊壁的极性差异,产生相分离,采用不同的机械搅拌速度,如采用200~1000转/分(rpm)的机械搅拌速度,使囊芯组合物在树脂溶液中形成不同粒径大小的颗粒悬浮液,最终经过滤、筛分、干燥、固化等工艺,从而制得具有不同粒径大小的微胶囊颗粒,微胶囊粒径在10~100nm。
表2微胶囊组分及其质量分数表
Figure BDA00003513296300082
三、平坦保护层用组合物的制备方法
实施例10~14是制备平坦保护层用组合物的实施例。将表3中质量分数为1%~10%的微胶囊,质量分数为1%~20%的含环氧基团的丙烯酸酯树脂,质量分数为1%~20%的固化剂,质量分数为70.5%~83.5%的有机溶剂,质量分数为0.01%~2%的助剂混合均匀,得到本发明平坦保护层用组合物。
表3平坦保护层用组合物的组分及其质量分数表
Figure BDA00003513296300091
四、平坦保护层的制备
彩膜基板制备工艺中常常存在各种形式的缺陷,为了及时准确的发现这些缺陷,在生产线上均配备有自动光学检测系统(Automatic Optic Inspection);该设备可通过对比破损修复处与正常完好处的光学差异,准确掌握缺陷位置,并可监测修复效果;
使用本发明平坦保护层用组合物制备平坦保护层的方法:
将本发明制备的平坦保护层用组合物涂覆于清洗干净的已涂覆黑矩阵、及彩色光阻层的玻璃基板上,真空干燥30~240s后,最终在200~250℃的烘烤炉内烘烤20~50min,即制得应用本发明彩膜基板的平坦保护层用组合物的平坦保护层。
五、检测方法
平坦保护层的形貌可通过光学显微镜、扫描电镜(SEM)、透射电镜(TEM)等检测手段进行检测。
通过检测可以发现,由于污染颗粒存在或外力的划伤,会造成平坦保护层出现破损,现有技术制备的平坦保护层,其缺陷率在0.01%左右,而采用本发明平坦保护层用组合物制备的平坦保护层基本无破损,其缺陷率为现有平坦保护层缺陷率的10%左右,这是由于破损引起的剪切作用力迫使微胶囊囊壁破损,使得微胶囊囊芯组合物流出,填充满破损处,经过一曝光处理,即可完成对破损的修补,大大提升TFT-LCD的产品良率与产品品质。
显然,本领域的技术人员可以对本发明进行各种改动和变型而不脱离本发明的精神和范围。这样,倘若本发明的这些修改和变型属于本发明权利要求及其等同技术的范围之内,则本发明也意图包含这些改动和变型在内。

Claims (10)

1.一种平坦保护层用组合物,其特征在于,包括质量分数为1%~10%的微胶囊,所述微胶囊囊壁包括碱不溶性树脂,所述微胶囊囊芯包括:
质量分数为30%~60%的可进行光固化的不饱和树脂低聚物;
质量分数为30%~60%的光聚合单体;
质量分数为1%~10%的光敏剂;
质量分数为0%~5%的添加剂。
2.如权利要求1所述的平坦保护层用组合物,其特征在于,所述可进行光固化的不饱和树脂低聚物包括环氧丙烯酸树脂、聚酯丙烯酸树脂、聚氨酯丙烯酸酯中的一种或几种;所述光聚合单体包括二季戊四醇六丙烯酸酯、三羟甲基丙烷三丙烯酸酯、季戊四醇四丙烯酸酯、二季戊四醇五丙烯酸酯中的一种或几种;所述光敏剂包括安息香、安息香双甲醚、二苯基乙酮、α-羟烷基苯酮、芳酰基膦氧化物、双苯甲酰基苯基氧化膦、二苯甲酮、2,4-二羟基二苯甲酮、硫代丙氧基硫杂蒽酮、异丙基硫杂蒽酮中的一种或几种。
3.如权利要求1所述的平坦保护层用组合物,其特征在于,还包括:
质量分数为1%~20%的含环氧基团的丙烯酸酯树脂;
质量分数为1%~20%的固化剂;
质量分数为70.5%~83.5%的有机溶剂;
质量分数为0.01%~2%的助剂。
4.如权利要求3所述的平坦保护层用组合物,其特征在于,所述含环氧基团的丙烯酸酯树脂包括丙烯酸甲酯改性环氧树脂、甲基丙烯酸甲酯改性环氧树脂、丙烯酸乙酯改性环氧树脂、甲基丙烯酸乙酯改性环氧树脂、丙烯酸丁酯改性环氧树脂、甲基丙烯酸丁酯改性环氧树脂、丙烯酸酯共聚物改性环氧树脂或甲基丙烯酸酯共聚物改性环氧树脂中的一种或多种;所述固化剂包括马来酸酐、邻苯二甲酸酐、偏苯三甲酸酐、聚酰胺树脂中的一种或多种;所述有机溶剂包括丙二醇单甲醚醋酸酯、3-乙氧基丙酸乙酯中的一种或多种。
5.如权利要求1所述的平坦保护层用组合物,其特征在于,所述碱不溶性树脂包括环氧树脂或聚氨酯树脂。
6.如权利要求3所述的平坦保护层用组合物,其特征在于,所述添加剂和所述助剂分别为附着力促进剂和流平剂中的一种或多种。
7.一种显示装置,包括彩膜基板,其特征在于,所述彩膜基板中的平坦保护层采用如权利要求1~6中任一项所述的平坦保护层用组合物得到。
8.一种平坦保护层用组合物的制备方法,其特征在于,包括:
将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合后进行分散,制得微胶囊囊芯用组合物;
将所述微胶囊囊芯用组合物滴加于微胶囊囊壁的溶液中,形成微胶囊;
取质量分数为1%~10%的微胶囊与平坦保护层用组合物的组分混合,形成平坦保护层用组合物。
9.如权利要求8所述的平坦保护层用组合物的制备方法,其特征在于,平坦保护层用组合物的组分包括质量分数为1%~20%的含环氧基团的丙烯酸酯树脂;质量分数为1%~20%的固化剂;质量分数为70.5%~83.5%的有机溶剂;质量分数为0.01%~2%的助剂。
10.如权利要求8所述的平坦保护层用组合物的制备方法,其特征在于,所述将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合后进行分散具体为:
将质量分数为30%~60%的可进行光固化的不饱和树脂低聚物,质量分数为30%~60%的光聚合单体,质量分数为1%~10%的光敏剂,以及质量分数为0%~5%的添加剂混合形成混合物;
将所述混合物在搅拌下分散1~4小时,所述搅拌的转速为300~1000转/分。
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