WO2013031799A1 - 無機酸化物透明分散液と透明複合体形成用樹脂組成物及び透明複合体並びに光学部材 - Google Patents
無機酸化物透明分散液と透明複合体形成用樹脂組成物及び透明複合体並びに光学部材 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G23/00—Compounds of titanium
- C01G23/04—Oxides; Hydroxides
- C01G23/047—Titanium dioxide
- C01G23/053—Producing by wet processes, e.g. hydrolysing titanium salts
- C01G23/0536—Producing by wet processes, e.g. hydrolysing titanium salts by hydrolysing chloride-containing salts
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G25/00—Compounds of zirconium
- C01G25/02—Oxides
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/0427—Coating with only one layer of a composition containing a polymer binder
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/05—Alcohols; Metal alcoholates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/06—Ethers; Acetals; Ketals; Ortho-esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K9/00—Use of pretreated ingredients
- C08K9/04—Ingredients treated with organic substances
- C08K9/06—Ingredients treated with organic substances with silicon-containing compounds
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- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/36—Compounds of titanium
- C09C1/3607—Titanium dioxide
- C09C1/3684—Treatment with organo-silicon compounds
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
- C09C3/12—Treatment with organosilicon compounds
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/64—Nanometer sized, i.e. from 1-100 nanometer
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2433/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
Definitions
- the present invention relates to a transparent inorganic oxide dispersion, a resin composition for forming a transparent composite, a transparent composite, and an optical member, and more particularly, an inorganic oxide is suitably used as a filler material for an organic resin, and the transparent resin Inorganic oxide transparent dispersion capable of improving optical and mechanical properties of the resin while maintaining the properties, and a resin composition for forming a transparent composite comprising the inorganic oxide transparent dispersion and the resin, and
- the present invention relates to a transparent composite formed using the resin composition for forming a transparent composite, and an optical member provided with the transparent composite.
- optical members such as lenses, prisms, optical waveguides, and optical films constituting the internal optical system of the optical product, high refractive index, and wavelength dispersion of the refractive index
- thermal characteristics such as thermal expansibility with respect to changes in environmental temperature, and mechanical characteristics such as mechanical strength with respect to external forces are important.
- adhesiveness with the base material used as the object which provides an optical film is also important.
- an organic resin such as an epoxy resin, an acrylic resin, a polyester resin, or a polycarbonate resin is used as the resin used for the optical member.
- an organic resin such as an epoxy resin, an acrylic resin, a polyester resin, or a polycarbonate resin
- transparent composites that have been compounded by adding inorganic oxide particles to the organic resins have been proposed.
- the inorganic oxide particles to be added are appropriately selected according to the optical properties, thermal properties and mechanical properties for which a transparent composite is required. For example, when it is desired to increase the refractive index of the organic resin, zirconia or titania having a high refractive index is selected as the metal oxide.
- the inorganic oxide particles are dispersed in a solvent to obtain an inorganic oxide dispersion, and this inorganic oxide is dispersed.
- the product dispersion and the resin are mixed to obtain a transparent composite-forming resin composition.
- the resin composition for forming a transparent composite is poured into a mold, the solvent is removed by heating or drying under reduced pressure for each mold, and then heating or irradiation with ultraviolet rays is performed.
- the resin can be cured to obtain a transparent composite having a predetermined shape.
- this transparent composite-forming resin composition onto a transparent plastic substrate by spin coating or screen printing, the resin composition is heated or dried under reduced pressure for each transparent plastic substrate. After removing the solvent, the resin is cured by heating or irradiating with ultraviolet rays or the like to obtain a predetermined film-like transparent composite.
- a non-polar low-polarity organic resin having a low polarity is used as the resin.
- the resin in order to uniformly disperse the inorganic oxide particles in such a low polar organic resin without being unevenly distributed, it is necessary to ensure the interface affinity between the surface of the inorganic oxide particles and the low polar organic resin. Therefore, it is necessary to modify the surface of the inorganic oxide particles so that the surface has the same low polarity as the low polarity organic resin.
- the surface of the metal oxide particles is treated with a surface modifier having a reactive group, and the surface-modified metal oxide particles are placed in a low polarity solvent such as toluene or methyl ethyl ketone. Dispersed dispersions and curable compositions have been proposed (see Patent Documents 1 to 3, etc.).
- the dispersions and curable compositions proposed in the conventional Patent Documents 1 to 3 have the following problems.
- a dispersion or curable composition using a low-polarity solvent such as toluene
- the low-polarity solvent is likely to erode the plastic substrate. Therefore, conditions for producing a transparent composite, particularly a dispersion or a curable composition, are used.
- the time that the low polar solvent is in contact with the plastic substrate, the thickness of the transparent composite, the processing conditions such as the heating temperature, etc. the resulting composite may not be sufficiently transparent There was no problem.
- the surface of the metal oxide particles used in the dispersion or the curable composition is treated with a surface modifier with low polarity, the surface of the surface modified metal oxide particles exhibits low polarity.
- examples of the highly polar solvent that hardly erodes the plastic substrate include alcohols and ethers. Accordingly, it is very difficult to uniformly disperse the low-polarity surface-modified metal oxide particles in a high-polarity solvent that hardly erodes the plastic substrate.
- the dispersibility of the surface-modified metal oxide particles in the obtained dispersion or curable composition is poor, and as a result, when this dispersion or curable composition is used, the transparency is high. There was a problem that a complex could not be obtained.
- the present invention has been made in view of the above circumstances, and by uniformly dispersing inorganic oxide particles in a highly polar solvent, the optical properties and mechanical properties of the resin can be maintained while maintaining the transparency of the resin.
- An object is to provide an inorganic oxide transparent dispersion, a transparent composite-forming resin composition, a transparent composite, and an optical member that can be improved.
- the present inventors have added a basic substance to a dispersion containing inorganic oxide particles modified with a surface modifier and a highly polar solvent, It has been found that the dispersibility of the inorganic oxide particles in the highly polar solvent is improved, and the present invention has been completed.
- the inorganic oxide transparent dispersion of the present invention is a cured resin obtained by dissolving an inorganic oxide particle modified with a surface modifier and having an average dispersed particle diameter of 1 nm to 50 nm and a resin.
- a highly polar solvent that hardly erodes and a basic substance
- the highly polar solvent is one or two of alcohols and ethers.
- the inorganic oxide particles are preferably composed mainly of any one of metal oxide particles and non-metal oxide particles.
- the resin composition for forming a transparent composite of the present invention is characterized by containing the inorganic oxide transparent dispersion of the present invention and a resin.
- the transparent composite of the present invention is characterized by being formed using the resin composition for forming a transparent composite of the present invention.
- the optical member of the present invention is characterized by comprising the transparent composite of the present invention.
- inorganic oxide particles modified with a surface modifier and having an average dispersed particle diameter of 1 nm or more and 50 nm or less, and a cured resin obtained by dissolving the resin and curing the resin Contains a highly polar solvent that hardly erodes and a basic substance, and further, the highly polar solvent is one or two of alcohols and ethers. Dispersibility of the oxide particles in a highly polar solvent in the presence of a basic substance can be improved. Therefore, the inorganic oxide particles modified with the surface modifier can be well dispersed in the highly polar solvent. As a result, by using the above inorganic oxide transparent dispersion, the production conditions of the transparent composite can be satisfied. However, a transparent composite that is stable and excellent in transparency can be easily obtained.
- the inorganic oxide transparent dispersion of this embodiment is a cured resin formed by dissolving an inorganic oxide particle modified with a surface modifier and having an average dispersed particle diameter of 1 nm to 50 nm and a resin. Is a dispersion containing a highly polar solvent that hardly erodes and a basic substance.
- Inorganic oxide particles As inorganic oxide particles used in the present embodiment, it is preferable that any one of metal oxide particles and nonmetal oxide particles is a main component.
- metal oxide particles metal oxide particles generally used as a filler in a resin are preferably used. Examples of such metal oxide particles include zirconium oxide (ZrO 2 : zirconia) and titanium oxide.
- TiO 2 titania
- aluminum oxide Al 2 O 3 : alumina
- iron oxide Fe 2 O 3 , Fe 3 O 4
- copper oxide CuO
- zinc oxide ZnO
- yttrium oxide Y 2 O 3 : Yttria
- niobium oxide Nb 2 O 5
- molybdenum oxide MoO 3 , MoO 2
- indium oxide In 2 O 3
- tin oxide SnO 2
- tantalum oxide Ta 2 O 5 , TaO 2
- Tungsten oxide WO 3 , WO 2
- lead oxide PbO
- bismuth oxide Bi 2 O 3
- cerium oxide CeO 2 : ceria
- Antimony oxide Sb 2 O 3 , Sb 2 O 5
- Antimony oxide Sb 2 O 3 , Sb 2 O 5
- Antimony oxide Sb 2 O 3 , Sb 2 O 5
- Antimony oxide Sb 2 O 3 , Sb 2 O 5
- Antimony oxide Sb 2 O 3 ,
- non-metal oxide particles for example, silicon oxide (SiO 2 : silica) or boron oxide (B 2 O 3 ) that is generally used as a filler for resins can be used. These metal oxide particles and nonmetal oxide particles may be used alone or in combination of two or more.
- the obtained transparent composite when a transparent composite is produced using the inorganic oxide transparent dispersion of the present embodiment, the obtained transparent composite can be increased in refractive index. Zirconium (ZrO 2 : zirconia) or titanium oxide (TiO 2 : titania) is preferable.
- zirconium oxide (ZrO 2 ) particles zirconium oxide particles
- ZrO 2 ) particles zirconium oxide particles
- tetragonal zirconia particles are preferred.
- the reason why the tetragonal zirconia particles are preferable is that when the average dispersed particle size of the fine particles is reduced to 20 nm or less during the fine particle synthesis, the tetragonal zirconia particles are more preferable than the conventionally known monoclinic zirconia particles.
- the average dispersion particle size of the inorganic oxide particles in the inorganic oxide transparent dispersion is preferably 1 nm or more and 50 nm or less, more preferably 3 nm or more and 30 nm or less, and further preferably 5 nm or more and 20 nm or less. If the average dispersed particle size is less than 1 nm, it is difficult to produce the inorganic oxide particles themselves. On the other hand, if the average dispersed particle size exceeds 50 nm, a transparent composite prepared using this inorganic oxide transparent dispersion is not preferable. This is not preferable because the transparency in the body may deteriorate.
- the average dispersed particle diameter in this embodiment means that the cumulative volume percentage obtained as a result of measuring the particle diameter of the inorganic oxide particles in this inorganic oxide transparent dispersion by the dynamic light scattering method is 50% by volume.
- the content (% by mass) of the inorganic oxide particles in the inorganic oxide transparent dispersion is not particularly limited, and may be appropriately selected according to the production process for obtaining the transparent composite. Among these, in order to improve the handleability and improve the production efficiency, the content is preferably 1% by mass or more and 50% by mass or less, more preferably 10% by mass or more and 30% by mass or less.
- Such a surface modifier is not particularly limited as long as it is a surface modifier having good compatibility with the above-described resin, and examples thereof include a compound represented by the following formula (1).
- R is a vinyl group, an allyl group, a 3-glycidoxypropyl group, a 2- (3,4-epoxycyclohexyl) ethyl group, a 3-acryloxypropyl group, a 3-methacrylopropyl group, A styryl group, 3-aminopropyl group, N-2 (aminoethyl) 3-aminopropyl group, N-phenyl-3-aminopropyl group, 3-mercaptopropyl group, 3-isocyanatopropyl group, One or more selected from the group of 20 or less alkyl groups and phenyl groups, and R ′ is selected from the group of chlorine, hydroxy groups, alkoxy groups having 1 to 20 carbon atoms and acetoxy groups 1 or 2 or more, and X is 0, or an integer of 1 or more and 4 or less.
- silane coupling agents examples include silane coupling agents, titanium coupling agents, and modified silicones.
- silane coupling agents include vinyltrimethoxysilane, vinyltriethoxysilane, vinyltrichlorosilane, and vinyl.
- modified silicone examples include epoxy-modified silicone, epoxy-polyether-modified silicone, methacryl-modified silicone, phenol-modified silicone, methylstyryl-modified silicone, acrylic-modified silicone, alkoxy-modified silicone, and methylhydrogen silicone.
- the amount of modification on the surface of the inorganic oxide particles by the surface modifier is not particularly limited as long as the compatibility between the obtained surface-modified inorganic oxide particles and the above resin is good.
- the modification amount of the surface modifier is an inorganic oxide in order to balance the transparency of the inorganic oxide transparent dispersion and the refractive index of the resin. 5 mass% or more and 100 mass% or less are preferable with respect to the whole quantity of particle
- the highly polar solvent is preferably an alcohol or an ether that easily dissolves the above-mentioned resin or the resin described later, and is hard to be eroded by a cured resin obtained by curing the resin by heat curing or ultraviolet irradiation.
- These alcohols and ethers may be used alone or in combination of two of alcohols and ethers.
- dissolve the resin means that the resin before being cured by heat curing or ultraviolet irradiation can be dissolved.
- a highly polar solvent that dissolves the resin and hardens the cured resin and does not easily erode is, in other words, “a solubility in the uncured curable resin and a low solubility in the cured resin. It is a highly polar solvent with erodibility.
- the alcohols are preferably alcohols having 4 or less carbon atoms in the main chain.
- examples thereof include alcohol, ethylene glycol, propylene glycol, trimethylene glycol, 1,2-butylene glycol, 1,3-butylene glycol, tetramethylene glycol, and 2,3-butylene glycol. Of these, isopropyl alcohol is particularly preferable.
- ethers include ethylene glycol monomethyl ether (methyl cellosolve), ethylene glycol monoethyl ether (ethyl cellosolve), propylene glycol monomethyl ether, propylene glycol monoethyl ether, dipropylene glycol and the like, and particularly propylene glycol monomethyl ether. Is preferred.
- ethers may select and use only 1 type from said various ethers, and may mix and use 2 or more types.
- 1 type or 2 or more types are selected from the above various alcohols
- 1 type or 2 or more types are selected from the above various ethers, and these alcohols and ethers are mixed to mix alcohol and ether. It may be used as a solution.
- the basic substance in the present embodiment includes an alkali metal or alkaline earth metal hydroxide, ammonia, amines, etc., and a substance whose hydrogen ion index (pH) is greater than 7 when dissolved in water. There is no particular limitation as long as it is sufficient.
- Such basic substances include calcium hydroxide, magnesium hydroxide, manganese hydroxide, iron hydroxide, zinc hydroxide, copper hydroxide, lanthanum hydroxide, aluminum hydroxide, iron hydroxide, ammonia, ammonium hydroxide.
- Inorganic basic substances such as potassium hydroxide and sodium hydroxide.
- TETA tetramethylethylenediamine
- hexamethylenediamine aniline
- catecholamine phenethylamine
- the basic substance may be added by appropriately adjusting the amount necessary for improving the dispersibility of the inorganic oxide particles in the highly polar solvent.
- the content of the basic substance in the inorganic oxide transparent dispersion according to this embodiment is preferably 0.01% by mass or more and 10% by mass or less, more preferably 0.03% with respect to the total amount of the inorganic oxide particles. It is not less than 2% by mass and not more than 2% by mass.
- the content of the basic substance is less than 0.01% by mass with respect to the total amount of the inorganic oxide particles, the dispersibility of the inorganic oxide particles in the highly polar solvent is not improved, while the content is Even if it exceeds 10% by mass with respect to the total amount of the inorganic oxide particles, there is no significant difference in the dispersion effect of the inorganic oxide particles and it becomes an impurity, which is not preferable.
- the surface-modified inorganic oxide particles can be favorably dispersed in a highly polar solvent.
- the details of the mechanism for obtaining such an effect are unknown, but, for example, in the case of inorganic oxide particles whose surface is modified with a silane coupling agent, it is considered as follows.
- the alkoxy group of the silane coupling agent 2 that has modified the surface of the inorganic oxide particle 1 is hydrolyzed to become a hydroxyl group (OH group).
- This OH group is either hydrogen bonded or dehydrated.
- the condensation there will be a portion chemically bonded to the inorganic oxide particles 1 and an unbonded portion (OH group portion).
- the inorganic oxide transparent dispersion of this embodiment is a cured resin formed by dissolving an inorganic oxide particle modified with a surface modifier and having an average dispersed particle diameter of 1 nm to 50 nm and a resin. Can be easily obtained by uniformly mixing a highly polar solvent that hardly erodes and a basic substance.
- the inorganic oxide particles powders having a primary particle diameter of 1 nm or more and 10 nm or less may be used, or a dispersion in which these powders are dispersed in a dispersion medium may be used.
- inorganic oxide particles are prepared. For example, dilute aqueous ammonia is added to a metal salt solution in which a metal salt such as zirconium oxychloride octahydrate or titanium trichloride is dissolved in pure water while stirring to prepare a metal oxide precursor slurry. Next, an aqueous solution of an inorganic salt such as sodium sulfate is added to the slurry with stirring to obtain a mixture. The amount of the inorganic salt added at this time is 20 to 40% by mass with respect to the metal oxide equivalent value of the metal ion in the metal salt solution.
- a metal salt such as zirconium oxychloride octahydrate or titanium trichloride
- the mixture is dried in the air at 100 ° C. or higher and 150 ° C. or lower for 24 hours or longer and 36 hours or shorter to obtain a solid.
- the solid material is pulverized with an automatic mortar or the like and then fired in the air at 300 ° C. or more and 700 ° C. or less for 1 hour or more and 6 hours or less, for example, at 500 ° C. for 3 hours.
- this fired product is put into pure water and stirred to form a slurry.
- the added inorganic salt is washed and sufficiently removed, and then dried. Thereby, metal oxide particles which are a kind of inorganic oxide particles are obtained.
- the basic substance in addition to mixing with the inorganic oxide particles and the highly polar solvent when preparing the above inorganic oxide transparent dispersion, You may add when obtaining.
- the basic substance since the basic substance is reduced by solid-liquid separation or the like, it is necessary to adjust the amount of the basic substance added to the slurry in consideration of this reduction.
- the basic substance is 0.5% by mass or more and 10% by mass or less with respect to the metal oxide particles, preferably It is preferable to add 1% by mass or more and 5% by mass or less.
- the resin composition for forming a transparent composite according to this embodiment is a resin composition containing the inorganic oxide transparent dispersion of this embodiment and a resin.
- the resin is not particularly limited as long as it is a resin that can be mixed with a highly polar solvent in an uncured state.
- melamine resin, phenol resin, polyester resin, urethane resin, acrylic resin, vinyl chloride resin, Polypropylene resin, polycarbonate resin, polyethylene terephthalate (PET) resin, epoxy resin, or the like can be used.
- an acrylic resin is preferable.
- the content rate of the inorganic oxide particle in this resin composition for transparent composite formation is 10 mass% or more and 60 mass% or less with respect to the total mass of an inorganic oxide particle and resin.
- This transparent composite-forming resin composition may be appropriately added with commonly used additives such as an organic solvent and a photoinitiator as necessary.
- the method for producing the resin composition for forming a transparent composite is not particularly limited as long as it is a method capable of uniformly mixing the inorganic oxide particle transparent dispersion of the present embodiment and the resin, and is publicly known. These stirring methods can be used.
- the transparent composite of this embodiment is a composite transparent to visible light formed using the resin composition for forming a transparent composite of this embodiment.
- the transmittance of the transparent composite in the visible light region in the wavelength range of 400 nm to 800 nm is preferably 80% or more, more preferably 90% or more when the thickness of the transparent composite is 30 ⁇ m.
- the transparent composite is prepared by pouring the transparent composite forming resin composition of the present embodiment into a mold having a predetermined shape, and then heating or depending on the type of the resin.
- a method of curing by applying ultraviolet irradiation or the like can be used.
- the plastic substrate is not particularly limited as long as it is a plastic substrate, and may be appropriately selected depending on the application.
- a plastic substrate include acrylic, acrylic containing highly elastic acrylic rubber, acrylic-styrene copolymer, polystyrene, polyethylene, polypropylene, polycarbonate, polyethylene terephthalate (PET), cyanuric acid triallyl ester ( TAC) and epoxy-like sheets and films.
- these plastic base materials may be used individually by 1 type among said base materials, and are good also as a laminated structure which laminated
- Examples of the coating method for forming this coating film include a bar coating method, a spin coating method, a dip coating method, a gravure coating method, a spray method, a roller method, and a brush coating method.
- the optical member of this embodiment includes the above-described transparent composite.
- the optical member may be an optical member using a transparent plastic substrate, and is not particularly limited.
- various cameras such as a camera, a film-integrated camera such as a lens-equipped film, a video camera, and an in-vehicle camera.
- Optical members and prism sheets used in various devices such as optical pickup lenses such as lenses, CDs, CD-ROMs, MOs, CD-Rs, CD-Videos, DVDs, OA devices such as microlens arrays, copying machines, printers, Examples include optical fiber communication devices and LED sealants.
- the method for mounting the transparent composite of the present embodiment on an optical member is not particularly limited, and may be mounted on the optical member by a known method.
- the inorganic oxide particles modified with the surface modifier and having an average dispersed particle diameter of 1 nm to 50 nm and the resin are dissolved and the resin is dissolved.
- the cured resin obtained by curing the resin contains a highly polar solvent that does not easily erode and a basic substance, so even inorganic oxide particles modified with a surface modifier are well dispersed in the highly polar solvent. Can be made.
- the resin composition for forming a transparent composite of the present embodiment since the resin was contained in the inorganic oxide transparent dispersion containing the surface-modified inorganic oxide particles, the highly polar solvent, and the basic substance, the surface-modified inorganic The oxide particles, the resin, and the cured resin obtained by curing the resin are uniformly mixed with a highly polar solvent that hardly erodes and a basic substance, and thus a transparent composite regardless of manufacturing conditions. Can be formed.
- the surface-modified inorganic oxide particles are uniformly dispersed in the resin, so that the surface-modified inorganic The characteristics and transparency of the oxide particles can be maintained.
- the properties of the surface-modified inorganic oxide particles can be imparted to this optical member while maintaining the transparency of the optical member. .
- Example 1 "Production of zirconia particles" To a zirconium salt aqueous solution in which 2615 g of zirconium oxychloride octahydrate was dissolved in 40 L of pure water, dilute ammonia water in which 344 g of 28% ammonia water was dissolved in 20 L of pure water was added with stirring to prepare a zirconia precursor slurry. Next, an aqueous sodium sulfate solution in which 300 g of sodium sulfate was dissolved in 5 L of pure water was added to this slurry with stirring. The amount of sodium sulfate added at this time was 30% by mass relative to the zirconia-converted value of zirconium ions in the zirconium salt aqueous solution.
- this mixture was dried in the air at 130 ° C. for 24 hours using a dryer to obtain a solid.
- the solid was pulverized with an automatic mortar and then baked at 500 ° C. for 1 hour in the air using an electric furnace to obtain a baked product.
- the fired product was put into pure water and stirred to form a slurry, and then the slurry was washed using a centrifuge, and the added sodium sulfate was sufficiently removed to obtain a solid.
- this solid substance was dried at 130 degreeC in air
- the average primary particle diameter of the zirconia particles was measured using a field emission electron microscope JEM-2100F (manufactured by JEOL Ltd.) and found to be 4 nm.
- the refractive index of zirconia was 2.15
- the refractive index of isopropyl alcohol was 1.37.
- the volume dispersed particle diameter (D50) when the cumulative volume percentage of the volume particle size distribution of the zirconia particles was 50% by volume was 6 nm.
- Example 2 As a basic substance, instead of 0.03 g of 28% ammonia water, 0.1 mol / L potassium hydroxide (KOH) isopropyl alcohol solution (containing about 19.4 mass% water: Kanto Chemical Co., Inc.) Product) A zirconia transparent dispersion of Example 2 was obtained in the same manner as in Example 1 except that 0.04 g was used. When the particle size distribution of zirconia in this zirconia transparent dispersion was measured in the same manner as in Example 1, the volume dispersed particle size (D50) was 7 nm.
- KOH potassium hydroxide
- Example 3 A zirconia transparent dispersion of Example 3 was obtained in the same manner as in Example 1 except that propylene glycol monomethyl ether (PGM) was used instead of isopropyl alcohol as the highly polar solvent.
- PGM propylene glycol monomethyl ether
- D50 volume dispersed particle size
- Example 4 "Production of titania particles" To a titanium salt aqueous solution in which 2445 g of titanium trichloride was dissolved in 40 L of pure water, dilute ammonia water in which 55 g of 28% ammonia water was dissolved in 20 L of pure water was added with stirring to prepare a titania precursor slurry. Next, an aqueous sodium nitrate solution in which 300 g of sodium nitrate was dissolved in 5 L of pure water was added to this slurry with stirring. The amount of sodium nitrate added at this time was 30% by mass with respect to titania equivalent of titanium ions in the titanium salt aqueous solution.
- this mixture was dried in the air at 130 ° C. for 24 hours using a dryer to obtain a solid.
- the solid was pulverized with an automatic mortar and then baked at 500 ° C. for 1 hour in the air using an electric furnace to obtain a baked product.
- the fired product was put into pure water and stirred to form a slurry, and then the slurry was washed using a centrifuge, and the added sodium nitrate was sufficiently removed to obtain a solid.
- this solid substance was dried at 130 degreeC in air
- the average primary particle diameter of the titania particles was measured using a field emission electron microscope JEM-2100F (manufactured by JEOL Ltd.) and found to be 6 nm.
- Example 4 Preparation of a transparent titania dispersion A titania transparent dispersion of Example 4 was obtained in the same manner as in Example 1 except that the above surface-modified titania particles were used instead of the surface-modified zirconia particles.
- the particle size distribution of titania in this titania transparent dispersion was measured in the same manner as in Example 1, the volume dispersed particle size (D50) was 8 nm.
- Comparative Example 1 7 g of isopropyl alcohol was added to 3 g of the surface-modified zirconia particles obtained according to Example 1 and stirred to obtain a zirconia dispersion liquid of Comparative Example 1 containing no basic substance.
- the particle size distribution of zirconia in this zirconia dispersion was measured in the same manner as in Example 1, the volume dispersed particle size (D50) was 154 nm, and the dispersibility was poor.
- Comparative Example 2 A zirconia dispersion of Comparative Example 2 was obtained in the same manner as in Example 1 except that methyl ethyl ketone (MEK) was used instead of isopropyl alcohol.
- MEK methyl ethyl ketone
- D50 volume dispersed particle size
- Comparative Example 3 A zirconia dispersion of Comparative Example 3 was obtained in the same manner as in Example 1 except that 0.04 g of water was used instead of 0.03 g of 28% ammonia water. When the particle size distribution of zirconia in this zirconia dispersion was measured in the same manner as in Example 1, the volume dispersed particle size (D50) was 82 nm, and the dispersibility was poor.
- Example 5 "Preparation of a resin composition for forming a transparent composite" 5 g of the zirconia transparent dispersion obtained according to Example 1, 5 g of acrylic resin PET-30 (manufactured by Nippon Kayaku Co., Ltd.), and 1- [4- (2-hydroxyethoxy) -phenyl] as a photopolymerization initiator -2-Hydroxy-2-methyl-1-propan-1-one Irgacure 2959 (manufactured by Ciba Specialty Chemicals) was mixed with 0.01 g to obtain a resin composition for forming a transparent composite of Example 5. .
- Example 6 The transparent composite of Example 6 was prepared in the same manner as in Example 5 except that the zirconia transparent dispersion obtained according to Example 2 was used instead of the zirconia transparent dispersion obtained according to Example 1. A resin composition for body formation was obtained.
- Example 7 The transparent composite of Example 7 was the same as Example 5 except that the zirconia transparent dispersion obtained according to Example 3 was used instead of the zirconia transparent dispersion obtained according to Example 1. A resin composition for body formation was obtained.
- Example 8 The transparent composite of Example 8 was prepared in the same manner as in Example 5 except that the transparent dispersion of titania obtained according to Example 4 was used instead of the transparent dispersion of zirconia obtained according to Example 1. A resin composition for body formation was obtained.
- Comparative Example 4 Complex formation of Comparative Example 4 was performed in the same manner as Example 5 except that the zirconia transparent dispersion obtained according to Comparative Example 1 was used instead of the zirconia transparent dispersion obtained according to Example 1. A resin composition was obtained.
- Comparative Example 5 Complex formation of Comparative Example 5 was performed in the same manner as in Example 5 except that the zirconia transparent dispersion obtained according to Comparative Example 2 was used instead of the zirconia transparent dispersion obtained according to Example 1. A resin composition was obtained.
- Comparative Example 6 Complex formation of Comparative Example 6 was performed in the same manner as Example 5 except that the zirconia transparent dispersion obtained according to Comparative Example 3 was used instead of the zirconia transparent dispersion obtained according to Example 1. A resin composition was obtained.
- Example 9 "Production of transparent composites"
- the resin composition for forming a transparent composite obtained according to Example 5 was applied onto a polycarbonate substrate by a bar coating method to form a coating film.
- this coated polycarbonate substrate was dried in an electric furnace at 60 ° C. for 5 minutes, and then irradiated with ultraviolet rays with a high-pressure mercury lamp to cure the resin in the coated film, whereby a 30 ⁇ m thick transparent composite was obtained. Obtained.
- the total light transmittance of the transparent composite that is, the total of the polycarbonate substrate and the coating film
- V-570 manufactured by JASCO
- the measurement results are shown in FIG. According to FIG. 2, the transmittance for light with a wavelength of 400 nm was 91%.
- Example 10 instead of the transparent composite-forming resin composition obtained according to Example 5, the same procedure as in Example 9 was used except that the transparent composite-forming resin composition obtained according to Example 6 was used. Thus, a transparent composite of Example 10 having a thickness of 30 ⁇ m was obtained. Subsequently, when the light transmittance of this transparent composite was measured according to Example 9, the transmittance for light having a wavelength of 400 nm was 90%.
- Example 11 Instead of the transparent composite-forming resin composition obtained according to Example 5, the same procedure as in Example 9 was used, except that the transparent composite-forming resin composition obtained according to Example 7 was used. Thus, a transparent composite of Example 11 having a thickness of 30 ⁇ m was obtained. Subsequently, when the light transmittance of this transparent composite was measured according to Example 9, the transmittance for light having a wavelength of 400 nm was 91%.
- Example 12 Instead of the transparent composite-forming resin composition obtained according to Example 5, the same procedure as in Example 9 was used, except that the transparent composite-forming resin composition obtained according to Example 8 was used. Thus, a transparent composite of Example 12 having a thickness of 30 ⁇ m was obtained. Subsequently, when the light transmittance of this transparent composite was measured according to Example 9, the transmittance for light having a wavelength of 400 nm was 92%.
- Example 7 instead of the transparent composite-forming resin composition obtained according to Example 5, the same procedure as in Example 9 was used, except that the composite-forming resin composition obtained according to Comparative Example 4 was used. A composite of Comparative Example 7 having a thickness of 30 ⁇ m was obtained. Subsequently, when the light transmittance of this composite was measured according to Example 9, the transmittance for light having a wavelength of 400 nm was as low as 12%. This is considered to be due to the poor dispersibility of the zirconia particles in the highly polar solvent, and hence the zirconia particles aggregated to reduce the transparency of the composite.
- Example 8 instead of the transparent composite-forming resin composition obtained according to Example 5, the same procedure as in Example 9 was used except that the composite-forming resin composition obtained according to Comparative Example 5 was used. A composite of Comparative Example 8 having a thickness of 30 ⁇ m was obtained. Subsequently, when the light transmittance of this composite was measured according to Example 9, the transmittance for light having a wavelength of 400 nm was as low as 75%. This is considered to be due to the devitrification of the polycarbonate base material because the methyl base ketone (MEK) eroded the polycarbonate base material.
- MEK methyl base ketone
- Comparative Example 9 instead of the resin composition for forming a transparent complex obtained according to Example 5, the resin composition for forming a complex obtained according to Comparative Example 6 was used in the same manner as in Example 9. A composite of Comparative Example 9 having a thickness of 30 ⁇ m was obtained. Subsequently, when the light transmittance of this composite was measured according to Example 9, the transmittance for light having a wavelength of 400 nm was as low as 75%.
- the zirconia dispersion was prepared by using water instead of 28% ammonia water, so that the dispersibility of the zirconia particles in the highly polar solvent was poor, and therefore the dispersibility of the zirconia particles in the obtained composite was low. This is thought to be due to the decline. From the above, it was confirmed that a basic substance was required instead of water in order to satisfactorily disperse the surface-modified zirconia particles having a reduced surface polarity in a highly polar solvent.
- the present invention provides an inorganic oxide transparent dispersion that enables an inorganic oxide to be suitably used as a filler material for an organic resin, and to improve the optical properties and mechanical properties of the resin while maintaining the transparency of the resin;
- a resin composition for forming a transparent composite comprising the inorganic oxide transparent dispersion and a resin, a transparent composite formed using the resin composition for forming a transparent composite, and the transparent composite It can be applied to optical members.
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Abstract
Description
本願は、2011年8月31日に、日本に出願された特願2011-188631号に基づき優先権を主張し、その内容をここに援用する。
添加する無機酸化物粒子は、透明複合体が要求される光学的特性、熱的特性及び機械的特性に合わせて適宜選択される。例えば、有機樹脂の屈折率を高めたい場合には、金属酸化物として屈折率の高いジルコニアやチタニア等が選択される。
そして、この透明複合体形成用樹脂組成物を成形型に流し込み、この樹脂組成物を成形型毎、加温または減圧乾燥することにより溶媒を除去し、その後、加熱または紫外線等を照射することにより樹脂を硬化させ、所定形状の透明複合体を得ることができる。
また、この透明複合体形成用樹脂組成物を、スピンコート法やスクリーン印刷法により透明プラスチック基材の上に塗布し、この樹脂組成物を透明プラスチック基材毎、加温または減圧乾燥することにより溶媒を除去し、その後、加熱または紫外線等を照射することにより樹脂を硬化させ、所定の膜状の透明複合体を得ることができる。
一方、このような低極性有機樹脂中に無機酸化物粒子を偏在することなく均一に分散させるためには、無機酸化物粒子の表面と低極性有機樹脂との界面親和性を確保する必要があり、そこで、無機酸化物粒子に表面修飾を施して、その表面を低極性有機樹脂と同程度の低極性とする必要がある。
この透明複合体を光学部材に適用する場合、より透明な複合体を得るためには、この透明複合体中の無機酸化物粒子の分散状態をより単分散状態に近づける必要があり、そのためには、低極性有機樹脂と混合する無機酸化物分散液中の無機酸化物粒子の分散性を向上させる必要が有り、また、この無機酸化物分散液の透明性も高める必要がある。
(1)トルエン等の低極性溶媒を用いた分散液や硬化性組成物では、低極性溶媒がプラスチック基材を侵食し易く、したがって、透明複合体を作製する条件、特に分散液や硬化性組成物が塗布されるプラスチック基材の種類、プラスチック基材に低極性溶媒が接触している時間、透明複合体の厚み、加熱温度等の処理条件によっては、得られる複合体の透明性が十分ではないという問題点があった。
なお、この形態は、発明の趣旨をより良く理解させるために具体的に説明するものであり、特に指定のない限り、本発明を限定するものではない。
本実施形態の無機酸化物透明分散液は、表面修飾剤により修飾され平均分散粒径が1nm以上かつ50nm以下の無機酸化物粒子と、樹脂を溶解するとともに前記樹脂を硬化してなる硬化樹脂には浸食し難い高極性溶媒と、塩基性物質とを含有してなる分散液である。
本実施形態にて用いられる無機酸化物粒子としては、金属酸化物粒子、非金属酸化物粒子のうちいずれか1種を主成分とすることが好ましい。
金属酸化物粒子としては、一般的に樹脂にフィラーとして使用される金属酸化物粒子が好適に用いられ、このような金属酸化物粒子としては、例えば、酸化ジルコニウム(ZrO2:ジルコニア)、酸化チタン(TiO2:チタニア)、酸化アルミニウム(Al2O3:アルミナ)、酸化鉄(Fe2O3、Fe3O4)、酸化銅(CuO)、酸化亜鉛(ZnO)、酸化イットリウム(Y2O3:イットリア)、酸化ニオブ(Nb2O5)、酸化モリブデン(MoO3、MoO2)、酸化インジウム(In2O3)、酸化スズ(SnO2)、酸化タンタル(Ta2O5、TaO2)、酸化タングステン(WO3、WO2)、酸化鉛(PbO)、酸化ビスマス(Bi2O3)、酸化セリウム(CeO2:セリア)、酸化アンチモン(Sb2O3、Sb2O5)等を用いることができる。
これらの金属酸化物粒子及び非金属酸化物粒子は、1種のみを単独で用いてもよく、2種以上を混合して用いてもよい。
これらの無機酸化物粒子の中でも、本実施形態の無機酸化物透明分散液を用いて透明複合体を作製した場合に、得られた透明複合体を高屈折率化させることができる点で、酸化ジルコニウム(ZrO2:ジルコニア)または酸化チタン(TiO2:チタニア)が好ましい。
正方晶ジルコニア粒子が好ましい理由は、微粒子合成の際に、微粒子の平均分散粒径が20nm以下のように小さくなると、正方晶ジルコニア粒子の方が、従来知られている単斜晶ジルコニア粒子よりも安定になり、硬度が高く、この正方晶ジルコニア粒子を樹脂中に分散させた樹脂複合体の機械的特性が向上し、さらには、この樹脂複合体においては、単斜晶ジルコニア粒子を添加した場合と比べて、マルテンサイト変態と称される体積膨張により高い靭性を示すからである。
なお、所望の特性を失わない範囲であれば、立方晶ジルコニア粒子が含有されていてもよい。
平均分散粒径が1nm未満では、無機酸化物粒子自体の製造が困難となるので好ましくなく、一方、平均分散粒径が50nmを超えると、この無機酸化物透明分散液を用いて作製した透明複合体における透明性が悪化する虞があるので好ましくない。
なお、本実施形態における平均分散粒径とは、この無機酸化物透明分散液中の無機酸化物粒子の粒子径を動的光散乱法により測定した結果得られた累積体積百分率が50体積%における体積分散粒径(D50)のことである。
このような表面修飾剤としては、上記の樹脂との相溶性がよい表面修飾剤であれば特に限定されず、例えば、下記の式(1)で表される化合物が挙げられる。
Rx-Si-R’4-x ……(1)
この式(1)中、Rは、ビニル基、アリル基、3-グリシドキシプロピル基、2-(3,4エポキシシクロヘキシル)エチル基、3-アクリロキシプロピル基、3-メタクリロプロピル基、スチリル基、3-アミノプロピル基、N-2(アミノエチル)3-アミノプロピル基、N-フェニル-3-アミノプロピル基、3-メルカプトプロピル基、3-イソシアネートプロピル基、炭素数が1以上かつ20以下のアルキル基、フェニル基の群から選択される1種または2種以上であり、R’は、塩素、ヒドロキシ基、炭素数が1以上かつ20以下のアルコキシ基、アセトキシ基の群から選択される1種または2種以上であり、Xは0、または1以上かつ4以下の整数である。
この高極性溶媒は、上記の樹脂あるいは後述する樹脂を容易に溶解するとともに、この樹脂を加熱硬化あるいは紫外線照射等により硬化してなる硬化樹脂に対しては浸食し難いアルコール類、エーテル類が好ましく、これらのアルコール類及びエーテル類は、アルコール類及びエーテル類のうちいずれか1種のみを単独で用いてもよく、また、2種を混合して用いてもよい。
ここで、「樹脂を溶解する」とは、加熱硬化あるいは紫外線照射等により硬化する前の樹脂を溶解できることを意味する。すなわち、「樹脂を溶解するとともに前記樹脂を硬化してなる硬化樹脂には侵食し難い高極性溶媒」を換言すれば、「未硬化の硬化性樹脂に対する溶解性と、硬化後の前記樹脂に対する低い侵食性とを備えた高極性溶媒」となる。
また、エーテル類は、上記の各種エーテルのうちから1種のみを選択して用いてもよく、2種以上を混合して用いてもよい。
さらに、上記の各種アルコールのうちから1種または2種以上を選択し、上記の各種エーテルのうちから1種または2種以上を選択して、これらのアルコール及びエーテルを混合してアルコール・エーテル混合溶液として用いてもよい。
本実施形態における塩基性物質とは、アルカリ金属またはアルカリ土類金属の水酸化物、アンモニア、アミン類等を含み、かつ水に溶解した場合に水素イオン指数(pH)が7より大となる物質であればよく、特に限定されない。
このような塩基性物質としては、水酸化カルシウム、水酸化マグネシウム、水酸化マンガン、水酸化鉄、水酸化亜鉛、水酸化銅、水酸化ランタン、水酸化アルミニウム、水酸化鉄、アンモニア、水酸化アンモニウム、水酸化カリウム、水酸化ナトリウム等の無機塩基性物質が挙げられる。
これらの無機塩基性物質、アミン類、その他の塩基性物質は、1種のみを単独で用いてもよく、2種以上を混合して用いてもよい。
これらの中でも、取扱いが容易で、不純物として残留し難い点で、アンモニアが好ましい。
この塩基性物質の本実施形態の無機酸化物透明分散液における含有量は、無機酸化物粒子の全体量に対して0.01質量%以上かつ10質量%以下が好ましく、より好ましくは0.03質量%以上かつ2質量%以下である。
この塩基性物質の含有量が無機酸化物粒子の全体量に対して0.01質量%未満であると、無機酸化物粒子の高極性溶媒への分散性が改良せず、一方、含有量が無機酸化物粒子の全体量に対して10質量%を超えても、無機酸化物粒子の分散効果に顕著な差はなく、しかも不純物となるので、好ましくない。
このような効果が得られるメカニズムについては、詳細は不明であるが、例えば、シランカップリング剤にて表面修飾した無機酸化物粒子の場合には、次のように考えられる。
図1(a)に示すように、無機酸化物粒子1の表面を修飾したシランカップリング剤2のアルコキシ基は、加水分解して水酸基(OH基)となり、このOH基は、水素結合または脱水縮合により、無機酸化物粒子1と化学的に結合する部分と、未結合の部分(OH基の部分)とが存在することとなる。
このように、無機酸化物粒子1を表面修飾しているシランカップリング剤2を、一部の極性が高まったシランカップリング剤2’とすることで、高極性溶媒との分散性が向上するものと考えられる。
本実施形態の無機酸化物透明分散液は、表面修飾剤により修飾され平均分散粒径が1nm以上かつ50nm以下の無機酸化物粒子と、樹脂を溶解するとともに前記樹脂を硬化してなる硬化樹脂には浸食し難い高極性溶媒と、塩基性物質とを、均一に混合することにより、容易に得ることができる。
無機酸化物粒子は、一次粒子径が1nm以上かつ10nm以下の粉体を用いてもよく、これらの粉体を分散媒中に分散させた分散液を用いてもよい。
まず、無機酸化物粒子を作製する。
例えば、オキシ塩化ジルコニウム8水塩、三塩化チタン等の金属塩を純水に溶解させた金属塩溶液に、希アンモニア水を攪拌しながら加え、金属酸化物前駆体スラリーを調製する。
次いで、このスラリーに、硫酸ナトリウム等の無機塩の水溶液を攪拌しながら加え、混合物とする。このときの無機塩の添加量は、金属塩溶液中の金属イオンの金属酸化物換算値に対して20~40質量%とする。
次いで、この固形物を自動乳鉢等により粉砕した後、大気中、300℃以上かつ700℃以下にて、1時間以上かつ6時間以下、例えば、500℃にて3時間、焼成する。
次いで、この焼成物を純水中に投入し、攪拌してスラリー状とする。次いで、添加した無機塩を洗浄して十分に除去した後、乾燥させる。これにより、無機酸化物粒子の一種である金属酸化物粒子が得られる。
この状態では、表面修飾された無機酸化物粒子がスラリー中に分散、またはスラリーの底部に沈降した状態であるから、このスラリーに固液分離等を施すことにより、表面修飾された無機酸化物粒子を固形物の状態で回収する。この固形物を乾燥させることで、表面修飾剤により表面が修飾された無機酸化物粒子を得ることができる。
この場合、固液分離等により塩基性物質が減少してしまうので、この減少分を考慮してスラリーに添加する塩基性物質の量を調整する必要がある。
このスラリーに表面修飾剤を添加し混合する表面修飾工程で塩基性物質を添加する場合には、塩基性物質を金属酸化物粒子に対して0.5質量%以上かつ10質量%以下、好ましくは1質量%以上かつ5質量%以下添加するのが好ましい。
本実施形態の透明複合体形成用樹脂組成物は、本実施形態の無機酸化物透明分散液と樹脂とを含有してなる樹脂組成物である。
上記の樹脂としては、未硬化の状態で高極性溶媒と混合可能な樹脂であればよく、特に限定されないが、例えば、メラミン樹脂、フェノール樹脂、ポリエステル樹脂、ウレタン樹脂、アクリル樹脂、塩化ビニル樹脂、ポリプロピレン樹脂、ポリカーボネート樹脂、ポリエチレンテレフタレート(PET)樹脂、エポキシ樹脂等を用いることができる。これらの中でもアクリル樹脂が好ましい。
無機酸化物粒子の含有率を上記の範囲内として樹脂と混合させることにより、無機酸化物粒子の有する特性を付与しつつ、後述する複合体を形成する際のハンドリング性がよくなるので、好ましい。
この透明複合体形成用樹脂組成物を製造する方法としては、本実施形態の無機酸化物粒子透明分散液と樹脂とを均一に混合させることができる方法であればよく、特に限定されず、公知の撹拌方法を用いることができる。
本実施形態の透明複合体は、本実施形態の透明複合体形成用樹脂組成物を用いて形成された可視光線に対して透明な複合体である。
この透明複合体の可視光線領域の400nm~800nmの波長帯域における透過率は、この透明複合体の厚みが30μmの場合には、80%以上が好ましく、より好ましくは90%以上である。
また、塗膜を作製する場合、プラスチック基材上に本実施形態の透明複合体形成用樹脂組成物を塗布し、その後、必要に応じて加熱による熱硬化あるいは紫外線照射等による光硬化を施す方法等が挙げられる。
本実施形態の光学部材は、上記の透明複合体を備えている。
この光学部材としては、透明なプラスチック基材が用いられる光学部材であればよく、特に限定されないが、例えば、カメラ、レンズ付フィルム等のフィルム一体型カメラ、ビデオカメラ、車載用カメラ等の各種カメラレンズ、CD、CD-ROM、MO、CD-R、CD-Video、DVD等の光ピックアップレンズやマイクロレンズアレイ、複写機、プリンター等のOA機器等の各種機器に用いられる光学部材やプリズムシート、光ファイバー通信装置、LED用封止剤等が挙げられる。
「ジルコニア粒子の作製」
オキシ塩化ジルコニウム8水塩2615gを純水40Lに溶解させたジルコニウム塩水溶液に、28%アンモニア水344gを純水20Lに溶解させた希アンモニア水を攪拌しながら加え、ジルコニア前駆体スラリーを調整した。
次いで、このスラリーに、硫酸ナトリウム300gを5Lの純水に溶解させた硫酸ナトリウム水溶液を攪拌しながら加えた。このときの硫酸ナトリウムの添加量は、ジルコニウム塩水溶液中のジルコニウムイオンのジルコニア換算値に対して30質量%であった。
次いで、この焼成物を純水中に投入し攪拌してスラリー状とした後、このスラリーの洗浄を遠心分離機を用いて行い、添加した硫酸ナトリウムを十分に除去し、固形物を得た。
その後、この固形物を乾燥機を用いて、大気中、130℃にて24時間、乾燥させ、ジルコニア粒子を作製した。
このジルコニア粒子の平均一次粒子径を電界放射形電子顕微鏡 JEM-2100F(日本電子社製)を用いて測定したところ、4nmであった。
上記のジルコニア粒子10gに水10gを加え、撹拌・混合して、ジルコニア透明水分散液を作製した。次いで、このジルコニア透明水分散液に、表面修飾剤として3-アクリロキシプロピルトリメトキシシラン KBM-5103(信越化学(株)社製)を5g加えて混合し、ジルコニア粒子を表面修飾した。次いで、この表面修飾ジルコニア粒子を固液分離により水から分離し、乾燥機を用いて乾燥した。
上記の表面修飾ジルコニア粒子3gに、イソプロピルアルコール7g、塩基性物質として濃度が28%のアンモニア水0.03gを加えて攪拌し、ジルコニア透明分散液を得た。
次いで、このジルコニア透明分散液中のジルコニアの粒度分布を測定するために、このジルコニア透明分散液中のジルコニア粒子の含有量を1質量%に調整した分散液を作製し、この分散液中のジルコニアの粒度分布を、動的光散乱式粒子径分布測定装置(Malvern社製)を用いて測定した。ここでは、ジルコニアの屈折率を2.15、イソプロピルアルコールの屈折率を1.37とした。その結果、ジルコニア粒子の体積粒度分布の累積体積百分率が50体積%における体積分散粒径(D50)は6nmであった。
塩基性物質として、濃度が28%のアンモニア水0.03gの替わりに、0.1mol/Lの水酸化カリウム(KOH)イソプロピルアルコール溶液(約19.4質量%の水を含む:関東化学株式会社製)0.04gを用いた以外は、実施例1と同様にして、実施例2のジルコニア透明分散液を得た。
このジルコニア透明分散液中のジルコニアの粒度分布を、実施例1と同様にして測定したところ、体積分散粒径(D50)は7nmであった。
高極性溶媒として、イソプロピルアルコールの替わりにプロピレングリコールモノメチルエーテル(PGM)を用いた以外は、実施例1と同様にして、実施例3のジルコニア透明分散液を得た。
このジルコニア透明分散液中のジルコニアの粒度分布を、実施例1と同様にして測定したところ、体積分散粒径(D50)は6nmであった。
「チタニア粒子の作製」
三塩化チタン2445gを純水40Lに溶解させたチタン塩水溶液に、28%アンモニア水55gを純水20Lに溶解させた希アンモニア水を攪拌しながら加え、チタニア前駆体スラリーを調整した。
次いで、このスラリーに、硝酸ナトリウム300gを5Lの純水に溶解させた硝酸ナトリウム水溶液を攪拌しながら加えた。このときの硝酸ナトリウムの添加量は、チタン塩水溶液中のチタンイオンのチタニア換算値に対して30質量%であった。
次いで、この焼成物を純水中に投入し攪拌してスラリー状とした後、このスラリーの洗浄を遠心分離機を用いて行い、添加した硝酸ナトリウムを十分に除去し、固形物を得た。
その後、この固形物を乾燥機を用いて、大気中、130℃にて24時間、乾燥させ、チタニア粒子を作製した。
このチタニア粒子の平均一次粒子径を電界放射形電子顕微鏡 JEM-2100F(日本電子社製)を用いて測定したところ、6nmであった。
上記のチタニア粒子の表面を、実施例1と同様にして、表面修飾剤として3-アクリロキシプロピルトリメトキシシラン KBM-5103(信越化学(株)社製)を用いて表面修飾した。次いで、この表面修飾チタニア粒子を固液分離により水から分離し、乾燥機を用いて乾燥した。
表面修飾ジルコニア粒子の替わりに上記の表面修飾チタニア粒子を用いた以外は、実施例1と同様にして、実施例4のチタニア透明分散液を得た。
このチタニア透明分散液中のチタニアの粒度分布を、実施例1と同様にして測定したところ、体積分散粒径(D50)は8nmであった。
実施例1に準じて得られた表面修飾ジルコニア粒子3gに、イソプロピルアルコール7gを加えて攪拌し、塩基性物質を含有しない比較例1のジルコニア分散液を得た。
このジルコニア分散液中のジルコニアの粒度分布を、実施例1と同様にして測定したところ、体積分散粒径(D50)は154nmであり、分散性が悪かった。
イソプロピルアルコールの替わりにメチルエチルケトン(MEK)を用いた以外は、実施例1と同様にして、比較例2のジルコニア分散液を得た。
このジルコニア分散液中のジルコニアの粒度分布を、実施例1と同様にして測定したところ、体積分散粒径(D50)は6nmであった。
28%のアンモニア水0.03gの替わりに水0.04gを用いた以外は、実施例1と同様にして、比較例3のジルコニア分散液を得た。
このジルコニア分散液中のジルコニアの粒度分布を、実施例1と同様にして測定したところ、体積分散粒径(D50)は82nmであり、分散性が悪かった。
「透明複合体形成用樹脂組成物の作製」
実施例1に準じて得られたジルコニア透明分散液5gと、アクリル樹脂 PET-30(日本化薬社製)5gと、光重合開始剤として1-[4-(2-ヒドロキシエトキシ)-フェニル]-2-ヒドロキシ-2-メチル-1-プロパン-1-オン イルガキュア2959(チバ・スペシャルティ・ケミカルズ社製)0.01gとを混合し、実施例5の透明複合体形成用樹脂組成物を得た。
実施例1に準じて得られたジルコニア透明分散液の替わりに、実施例2に準じて得られたジルコニア透明分散液を用いた以外は、実施例5と同様にして、実施例6の透明複合体形成用樹脂組成物を得た。
実施例1に準じて得られたジルコニア透明分散液の替わりに、実施例3に準じて得られたジルコニア透明分散液を用いた以外は、実施例5と同様にして、実施例7の透明複合体形成用樹脂組成物を得た。
実施例1に準じて得られたジルコニア透明分散液の替わりに、実施例4に準じて得られたチタニア透明分散液を用いた以外は、実施例5と同様にして、実施例8の透明複合体形成用樹脂組成物を得た。
実施例1に準じて得られたジルコニア透明分散液の替わりに、比較例1に準じて得られたジルコニア分散液を用いた以外は、実施例5と同様にして、比較例4の複合体形成用樹脂組成物を得た。
実施例1に準じて得られたジルコニア透明分散液の替わりに、比較例2に準じて得られたジルコニア分散液を用いた以外は、実施例5と同様にして、比較例5の複合体形成用樹脂組成物を得た。
実施例1に準じて得られたジルコニア透明分散液の替わりに、比較例3に準じて得られたジルコニア分散液を用いた以外は、実施例5と同様にして、比較例6の複合体形成用樹脂組成物を得た。
「透明複合体の作製」
実施例5に準じて得られた透明複合体形成用樹脂組成物を、バーコート法によりポリカーボネート基板上に塗布し、塗膜を形成した。次いで、この塗膜付きポリカーボネート基板を、電気炉にて60℃にて5分間乾燥させた後、高圧水銀ランプにより紫外線を照射して塗膜中の樹脂を硬化させ、厚み30μmの透明複合体を得た。
この測定結果を図2に示す。
図2によれば、波長400nmの光に対する透過率は91%であった。
実施例5に準じて得られた透明複合体形成用樹脂組成物の替わりに、実施例6に準じて得られた透明複合体形成用樹脂組成物を用いた以外は、実施例9と同様にして、実施例10の厚み30μmの透明複合体を得た。
次いで、この透明複合体の光透過率を実施例9に準じて測定したところ、波長400nmの光に対する透過率は90%であった。
実施例5に準じて得られた透明複合体形成用樹脂組成物の替わりに、実施例7に準じて得られた透明複合体形成用樹脂組成物を用いた以外は、実施例9と同様にして、実施例11の厚み30μmの透明複合体を得た。
次いで、この透明複合体の光透過率を実施例9に準じて測定したところ、波長400nmの光に対する透過率は91%であった。
実施例5に準じて得られた透明複合体形成用樹脂組成物の替わりに、実施例8に準じて得られた透明複合体形成用樹脂組成物を用いた以外は、実施例9と同様にして、実施例12の厚み30μmの透明複合体を得た。
次いで、この透明複合体の光透過率を実施例9に準じて測定したところ、波長400nmの光に対する透過率は92%であった。
実施例5に準じて得られた透明複合体形成用樹脂組成物の替わりに、比較例4に準じて得られた複合体形成用樹脂組成物を用いた以外は、実施例9と同様にして、比較例7の厚み30μmの複合体を得た。
次いで、この複合体の光透過率を実施例9に準じて測定したところ、波長400nmの光に対する透過率は12%と低いものであった。これは、高極性溶媒中におけるジルコニア粒子の分散性が悪く、したがって、ジルコニア粒子同士が凝集して複合体の透明性を低下させたことによるものと考えられる。
実施例5に準じて得られた透明複合体形成用樹脂組成物の替わりに、比較例5に準じて得られた複合体形成用樹脂組成物を用いた以外は、実施例9と同様にして、比較例8の厚み30μmの複合体を得た。
次いで、この複合体の光透過率を実施例9に準じて測定したところ、波長400nmの光に対する透過率は75%と低いものであった。これは、ポリカーボネート基材をメチルエチルケトン(MEK)が侵食したために、ポリカーボネート基材が失透したことによるものと考えられる。
実施例5に準じて得られた透明複合体形成用樹脂組成物の替わりに、比較例6に準じて得られた複合体形成用樹脂組成物を用いた以外は、実施例9と同様にして、比較例9の厚み30μmの複合体を得た。
次いで、この複合体の光透過率を実施例9に準じて測定したところ、波長400nmの光に対する透過率は75%と低いものであった。
以上により、表面の極性を低下させた表面修飾ジルコニア粒子を高極性溶媒中に良好に分散させるためには、水ではなく塩基性物質が必要であることが確認された。
Claims (7)
- 表面修飾剤により修飾され平均分散粒径が1nm以上かつ50nm以下の無機酸化物粒子と、樹脂を溶解するとともに前記樹脂を硬化した硬化樹脂には浸食し難い高極性溶媒と、塩基性物質とを含有し、
前記高極性溶媒は、アルコール類及びエーテル類のうちいずれか1種または2種であることを特徴とする無機酸化物透明分散液。 - 前記無機酸化物粒子は、金属酸化物粒子、非金属酸化物粒子のうちいずれか1種を主成分とすることを特徴とする請求項1記載の無機酸化物透明分散液。
- 前記無機酸化物粒子は、金属酸化物粒子であることを特徴とする請求項1記載の無機酸化物透明分散液。
- 前記高極性溶媒が、イソプロピルアルコール及びプロピレングリコールモノメチルエーテルのうちいずれか一方または双方であることを特徴とする請求項1記載の無機酸化物透明分散液。
- 請求項1から4のいずれか1項記載の無機酸化物透明分散液と樹脂とを含有することを特徴とする透明複合体形成用樹脂組成物。
- 請求項5記載の透明複合体形成用樹脂組成物を用いて形成されていることを特徴とする透明複合体。
- 請求項6記載の透明複合体を備えていることを特徴とする光学部材。
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JP2013082609A (ja) * | 2011-09-30 | 2013-05-09 | Jgc Catalysts & Chemicals Ltd | 改質ジルコニア微粒子粉末、改質ジルコニア微粒子分散ゾルおよびその製造方法 |
JP2014196216A (ja) * | 2013-03-29 | 2014-10-16 | 日揮触媒化成株式会社 | 改質金属酸化物微粒子粉末、改質金属酸化物微粒子分散体およびその製造方法 |
WO2015046487A1 (ja) * | 2013-09-30 | 2015-04-02 | 住友大阪セメント株式会社 | 無機粒子分散液、無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、表示装置 |
JP2016020431A (ja) * | 2014-07-14 | 2016-02-04 | 住友大阪セメント株式会社 | 金属酸化物粒子分散液、金属酸化物粒子含有組成物、塗膜、表示装置 |
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JP2018053098A (ja) * | 2016-09-29 | 2018-04-05 | 住友大阪セメント株式会社 | 無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、および表示装置 |
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JP2013082609A (ja) * | 2011-09-30 | 2013-05-09 | Jgc Catalysts & Chemicals Ltd | 改質ジルコニア微粒子粉末、改質ジルコニア微粒子分散ゾルおよびその製造方法 |
JP2014196216A (ja) * | 2013-03-29 | 2014-10-16 | 日揮触媒化成株式会社 | 改質金属酸化物微粒子粉末、改質金属酸化物微粒子分散体およびその製造方法 |
WO2015046487A1 (ja) * | 2013-09-30 | 2015-04-02 | 住友大阪セメント株式会社 | 無機粒子分散液、無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、表示装置 |
JP2015091985A (ja) * | 2013-09-30 | 2015-05-14 | 住友大阪セメント株式会社 | 無機粒子分散液、無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、表示装置 |
JP5846322B2 (ja) * | 2013-09-30 | 2016-01-20 | 住友大阪セメント株式会社 | 無機粒子分散液、無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、表示装置 |
JP2016020431A (ja) * | 2014-07-14 | 2016-02-04 | 住友大阪セメント株式会社 | 金属酸化物粒子分散液、金属酸化物粒子含有組成物、塗膜、表示装置 |
JP2017014479A (ja) * | 2015-07-03 | 2017-01-19 | 住友大阪セメント株式会社 | 無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、および表示装置 |
JP2018053098A (ja) * | 2016-09-29 | 2018-04-05 | 住友大阪セメント株式会社 | 無機粒子含有組成物、塗膜、塗膜付きプラスチック基材、および表示装置 |
WO2021106747A1 (ja) * | 2019-11-29 | 2021-06-03 | 石原産業株式会社 | 二酸化チタン微粒子の有機溶剤分散体及びその製造方法、並びにその用途 |
JP6963202B1 (ja) * | 2019-11-29 | 2021-11-05 | 石原産業株式会社 | 二酸化チタン微粒子の有機溶剤分散体及びその製造方法、並びにその用途 |
Also Published As
Publication number | Publication date |
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EP2752392A1 (en) | 2014-07-09 |
EP2752392A4 (en) | 2015-04-29 |
US20140206801A1 (en) | 2014-07-24 |
TW201315746A (zh) | 2013-04-16 |
JP6028733B2 (ja) | 2016-11-16 |
CN103764567A (zh) | 2014-04-30 |
TWI532751B (zh) | 2016-05-11 |
JPWO2013031799A1 (ja) | 2015-03-23 |
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