WO2016007239A1 - Composition de revêtement dur durcissable par rayonnement - Google Patents

Composition de revêtement dur durcissable par rayonnement Download PDF

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Publication number
WO2016007239A1
WO2016007239A1 PCT/US2015/033619 US2015033619W WO2016007239A1 WO 2016007239 A1 WO2016007239 A1 WO 2016007239A1 US 2015033619 W US2015033619 W US 2015033619W WO 2016007239 A1 WO2016007239 A1 WO 2016007239A1
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WIPO (PCT)
Prior art keywords
composition
radiation
percent
polymers
meth
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Application number
PCT/US2015/033619
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English (en)
Inventor
Zhengwei Shi
Danliang Jin
Robert Petcavich
Xuanqi Zhang
Original Assignee
Uni-Pixel Displays, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Uni-Pixel Displays, Inc. filed Critical Uni-Pixel Displays, Inc.
Priority to CN201580021329.9A priority Critical patent/CN106414629B/zh
Priority claimed from US14/727,789 external-priority patent/US20150275040A1/en
Publication of WO2016007239A1 publication Critical patent/WO2016007239A1/fr

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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
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D133/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Coating compositions based on derivatives of such polymers
    • C09D133/04—Homopolymers or copolymers of esters
    • C09D133/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F222/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides, or nitriles thereof
    • C08F222/10—Esters

Definitions

  • Touch screens are commonly found in consumer, commercial, and industrial systems.
  • a touch screen allows a user to control various aspects of a system by touch or gestures directly on the touch screen itself.
  • a user may interact with one or more objects depicted on a display device by touch or gestures that are sensed by a touch sensor.
  • the touch sensor includes a conductive pattern disposed on a substrate that is configured to sense touch.
  • Touch sensors are prone to damage such as, for example, scratching and breakage, due to the increased level of direct contact.
  • touch screens typically include a transparent cover lens that overlays the touch sensor to protect the underlying components from environmental conditions, chemical agents, abrasion, and oxidation.
  • the transparent cover lens is conventionally composed of polyester or glass. While flexible, polyester can only provide a minimal level of hardness.
  • a transparent cover lens composed of polyester provides a pencil hardness in a range between HB and 4H that is susceptible to scratching and other failure modes. Glass provides improved hardness at the expense of flexibility.
  • a transparent cover lens composed of glass provides increased pencil hardness compared to polyester, but is inflexible and is susceptible to breakage and other failure modes.
  • a radiation-curable hard-coat composition includes a principal resin that includes multi-(meth)acrylate functionalized oligomers or polymers and a free radical- polymerization initiator.
  • the initiator includes at least two photo-initiators in a predetermined ratio that generate a highly reactive species when irradiated with radiation.
  • Figure 1A shows a cross section of a conventional touch screen.
  • Figure IB shows a cross section of a touch screen in accordance with one or more embodiments of the present invention.
  • Figure 2 shows a schematic view of a touch screen enabled system in accordance with one or more embodiments of the present invention.
  • Figure 3 shows a functional representation of a touch sensor as part of a touch screen in accordance with one or more embodiments of the present invention.
  • Figure 4 shows a cross-section of a touch sensor with conductive patterns disposed on opposing sides of a transparent substrate in accordance with one or more embodiments of the present invention.
  • Figure 5A shows a first conductive pattern disposed on a transparent substrate in accordance with one or more embodiments of the present invention.
  • Figure 5B shows a second conductive pattern disposed on a transparent substrate in accordance with one or more embodiments of the present invention.
  • Figure 5C shows a mesh area of a touch sensor in accordance with one or more embodiments of the present invention.
  • Figure 6 shows common commercially-available UV lamps and their spectral outputs in accordance with one or more embodiments of the present invention.
  • Figure 7 shows the photo-initiation efficiency of a radiation-curable hard-coat composition with different multi-constituent photo-initiator content in accordance with one or more embodiments of the present invention.
  • FIG. 1A shows a cross-section of a conventional touch screen 100.
  • Touch screen 100 includes a display device 110 and a touch sensor 130 that overlays a viewable area of display device 110.
  • Touch sensor 130 may be a capacitive, resistive, optical, acoustic, or any other type of touch sensor technology capable of sensing touch.
  • an optically clear adhesive (“OCA”) or optically clear resin (“OCR”) 140 bonds a bottom side of touch sensor 130 to a top, or user-facing, side of display device 110.
  • OCA optically clear adhesive
  • OCR optically clear resin
  • an isolation layer, or air gap, 140 separates the bottom side of touch sensor 130 from the top, or user- facing, side of display device 110.
  • a transparent cover lens 150 overlays a top, or user-facing, side of touch sensor 130.
  • the transparent cover lens 150 is composed of transparent polymers or glass.
  • an OCA or OCR 140 bonds a bottom side of the transparent cover lens 150 to the top, or user-facing, side of touch sensor 130.
  • a top side of transparent cover lens 150 faces the user and protects the underlying components of touch screen 100.
  • touch sensor 130, or the function that it implements, may be integrated into the display device 110 stack (not independently illustrated).
  • a radiation-curable hard-coat 160 may be used on a top, or user-facing side, of transparent cover lens (e.g., 150 of Figure 1A).
  • radiation-curable hard-coat 160 may be applied directly to the top, or user-facing, side of a transparent cover lens (e.g., 150 of Figure 1A). In this way, the top, or user-facing, side of radiation- curable hard-coat 160 serves as the interface between touch screen 102 and the end user.
  • FIG. IB shows a cross-section of a touch screen 102 in accordance with one or more embodiments of the present invention.
  • Touch screen 102 includes a display device 110.
  • Display device 110 may be a Liquid Crystal Display (“LCD”), Light- Emitting Diode (“LED”), Organic Light-Emitting Diode (“OLED”), Active Matrix Organic Light-Emitting Diode (“AMOLED”), In-Plane Switching (“IPS”), or other type of display device suitable for use as part of a touch screen application or design.
  • touch screen 102 may include a touch sensor 130 that overlays at least a portion of a viewable area of display device 110.
  • the viewable area of display device 110 may include the area defined by the light emitting pixels (not shown) of the display device 110 that are viewable to an end user.
  • an OCA or OCR 140 may bond a bottom side of touch sensor 130 to a top, or user-facing, side of display device 110.
  • an isolation layer, or air gap, 140 may separate the bottom side of touch sensor 130 from the top, or user-facing, side of display device 110.
  • a radiation-curable hard-coat 160 may be used instead of a transparent cover lens (e.g., 150 of Figure 1A).
  • radiation-curable hard-coat 160 may be applied directly to the top, or user-facing, side of touch sensor 130 in lieu of a bonding layer (e.g., 140 of Figure 1A) and a transparent cover lens (e.g., 150 of Figure 1A). In this way, the top, or user-facing, side of radiation-curable hard-coat 160 serves as the interface between touch screen 102 and the end user.
  • radiation-curable hard-coat 160 may be used to protect touch sensor 130 and an optional bonding layer 140 and/or an optional transparent cover lens 150 may be used.
  • Touch sensor 130 may be a capacitive, resistive, optical, acoustic, or any other type of touch sensor technology capable of sensing touch.
  • touch sensor 130, or the function that it implements may be integrated into the display device 110 stack (not independently illustrated).
  • the components and/or the stackup of touch screen 102 may vary based on an application or design.
  • FIG. 2 shows a schematic view of a touch screen enabled system 200 in accordance with one or more embodiments of the present invention.
  • Touch screen enabled system 200 may be a consumer, commercial, or industrial system including, but not limited to, a smartphone, tablet computer, laptop computer, desktop computer, server computer, printer, monitor, television, appliance, application specific device, kiosk, automatic teller machine, copier, desktop phone, automotive display system, portable gaming device, gaming console, or other application or design suitable for use with touch screen 100 or 102.
  • Touch screen enabled system 200 may include one or more printed circuit boards or flexible circuits (not shown) on which one or more processors (not shown), system memory (not shown), and other system components (not shown) may be disposed.
  • Each of the one or more processors may be a single-core processor (not shown) or a multi-core processor (not shown) capable of executing software instructions.
  • Multi-core processors typically include a plurality of processor cores disposed on the same physical die (not shown) or a plurality of processor cores disposed on multiple die (not shown) disposed within the same mechanical package (not shown).
  • System 200 may include one or more input/output devices (not shown), one or more local storage devices (not shown) including solid-state memory, a fixed disk drive, a fixed disk drive array, or any other non-transitory computer readable medium, a network interface device (not shown), and/or one or more network storage devices (not shown) including a network-attached storage device or a cloud-based storage device.
  • touch screen 100 or 102 may include touch sensor
  • Touch sensor 130 may include a viewable area 240 that corresponds to that portion of the touch sensor 130 that overlays the light emitting pixels (not shown) of display device 110 (e.g., viewable area 230 of display device 110).
  • Touch sensor 130 may include a bezel circuit 250 outside at least one side of the viewable area 240 that provides connectivity between touch sensor 130 and a controller 210.
  • touch sensor 130, or the function that it implements may be integrated into display device 110 (not independently illustrated).
  • Controller 210 electrically drives at least a portion of touch sensor 130. Touch sensor 130 senses touch (capacitance, resistance, optical, acoustic, or other technology) and conveys information corresponding to the sensed touch to controller 210.
  • controller 210 may recognize one or more gestures based on the sensed touch or touches.
  • Controller 210 provides host 220 with touch or gesture information corresponding to the sensed touch or touches. Host 220 may use this touch or gesture information as user input and respond in an appropriate manner. In this way, the user may interact with touch screen enabled system 200 by touch or gestures on touch screen 100 or 102.
  • host 220 may be the one or more printed circuit boards (not shown) or flexible circuits (not shown) on which the one or more processors (not shown) are disposed.
  • host 220 may be a subsystem (not shown) or any other part of system 200 (not shown) that is configured to interface with display device 110 and controller 210.
  • host 220 may be a subsystem (not shown) or any other part of system 200 (not shown) that is configured to interface with display device 110 and controller 210.
  • FIG. 3 shows a functional representation of a touch sensor 130 as part of a touch screen 100 or 102 in accordance with one or more embodiments of the present invention.
  • touch sensor 130 may be viewed as a plurality of column channels 310 and a plurality of row channels 320.
  • the plurality of column channels 310 and the plurality of row channels 320 may be separated from one another by, for example, a dielectric or substrate (not shown) on which they are disposed.
  • the number of column channels 310 and the number of row channels 320 may or may not be the same and may vary based on an application or a design.
  • the apparent intersections of column channels 310 and row channels 320 may be viewed as uniquely addressable locations of touch sensor 130.
  • controller 210 may electrically drive one or more row channels 320 and touch sensor 130 may sense touch on one or more column channels 310 that are sampled by controller 210.
  • controller 210 may electrically drive one or more row channels 320 and touch sensor 130 may sense touch on one or more column channels 310 that are sampled by controller 210.
  • controller 210 may interface with touch sensor 130 by a scanning process.
  • controller 210 may electrically drive a selected row channel 320 (or column channel 310) and sample all column channels 310 (or row channels 320) that intersect the selected row channel 320 (or the selected column channel 310) by sensing, for example, changes in capacitance.
  • the change in capacitance may be used to determine the location of the touch or touches.
  • This process may be continued through all row channels 320 (or all column channels 310) such that changes in capacitance are measured at each uniquely addressable location of touch sensor 130 at predetermined intervals.
  • Controller 210 may allow for the adjustment of the scan rate depending on the needs of a particular application or design.
  • controller 210 may interface with touch sensor 130 by an interrupt driven process.
  • a touch or a gesture generates an interrupt to controller 210 that triggers controller 210 to read one or more of its own registers that store sensed touch information sampled from touch sensor 130 at predetermined intervals.
  • controller 210 may vary based on an application or a design in accordance with one or more embodiments of the present invention.
  • Figure 4 shows a cross-section of a touch sensor 130 with conductive patterns
  • touch sensor 130 may include a first conductive pattern 420 disposed on a top, or user-facing, side of a transparent substrate 410 and a second conductive pattern 430 disposed on a bottom side of the transparent substrate 410.
  • the first conductive pattern 420 may overlay the second conductive pattern 430 at a predetermined alignment that may include an offset.
  • a conductive pattern may be any shape or pattern of one or more conductors (not shown) in accordance with one or more embodiments of the present invention.
  • touch sensor 130 conductor including, for example, metal conductors, metal mesh conductors, indium tin oxide (“ITO”) conductors, poly(3,4-ethylenedioxythiophene (“PEDOT”) conductors, carbon nanotube conductors, silver nanowire conductors, or any other conductors may be used in accordance with one or more embodiments of the present invention.
  • ITO indium tin oxide
  • PEDOT poly(3,4-ethylenedioxythiophene
  • carbon nanotube conductors carbon nanotube conductors
  • silver nanowire conductors or any other conductors
  • single-sided touch sensor 130 stackups may include conductors disposed on a single side of a substrate 410 where conductors that cross are isolated from one another by a dielectric material (not shown), such as, for example, as used in On Glass Solution ("OGS") touch sensor 130 embodiments.
  • Double-sided touch sensor 130 stackups may include conductors disposed on opposing sides of the same substrate 140 (as shown in Figure 4) or bonded touch sensor 130 embodiments (not shown) where conductors are disposed on at least two different sides of at least two different substrates 410.
  • Bonded touch sensor 130 stackups may include, for example, two single-sided substrates 410 bonded together (not shown), one double-sided substrate 410 bonded to a single- sided substrate 410 (not shown), or a double-sided substrate 410 bonded to another double-sided substrate 410 (not shown).
  • touch sensor 130 stackups including those that vary in the number, type, organization, and/or configuration of substrate(s) and/or conductive pattern(s) are within the scope of one or more embodiments of the present invention.
  • one of ordinary skill in the art will also recognize that one or more of the above-noted touch sensor 130 stackups may be used in applications where touch sensor 130 is integrated into display device 110.
  • a conductive pattern 420 or 430 may be disposed on one or more transparent substrates 410 by any process suitable for disposing conductive lines or features on a substrate. Suitable processes may include, for example, printing processes, vacuum-based deposition processes, solution coating processes, or cure/etch processes that either form conductive lines or features on substrate or form seed lines or features on substrate that may be further processed to form conductive lines or features on substrate.
  • Printing processes may include flexographic printing processes, including the flexographic printing of a catalytic ink that may be metallized by an electroless plating process to plate a metal on top of the printed catalytic ink or direct flexographic printing of conductive ink or other materials capable of being flexographically printed, gravure printing, inkjet printing, rotary printing, or stamp printing.
  • Deposition processes may include pattern-based deposition, chemical vapor deposition, electro deposition, epitaxy, physical vapor deposition, or casting.
  • Cure/etch processes may include optical or Ultra-Violet ("UV")-based photolithography, e-beam/ion-beam lithography, x-ray lithography, interference lithography, scanning probe lithography, imprint lithography, or magneto lithography.
  • UV Ultra-Violet
  • transparent substrate 410 With respect to transparent substrate 410, transparent means capable of transmitting a substantial portion of visible light through the substrate suitable for a given touch sensor application or design. In typical touch sensor applications, transparent means transmittance of at least 85 percent of incident visible light through the substrate. However, one of ordinary skill in the art will recognize that other transmittance values may be desirable for other touch sensor applications or designs.
  • transparent substrate 410 may be polyethylene terephthalate (“PET”), polyethylene naphthalate (“PEN”), cellulose acetate (“TAC”), cycloaliphatic hydrocarbons (“COP”), polymethylmethacrylates (“PMMA”), polyimide (“PI”), bi-axially-oriented polypropylene (“BOPP”), polyester, polycarbonate, glass, copolymers, blends, or combinations thereof.
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • TAC cellulose acetate
  • COP cycloaliphatic hydrocarbons
  • PMMA polymethylmethacrylates
  • PI polyimide
  • BOPP bi-axially-oriented polypropylene
  • Figure 5 A shows a first conductive pattern 420 disposed on a transparent substrate (e.g., transparent substrate 410) in accordance with one or more embodiments of the present invention.
  • first conductive pattern 420 may include a mesh formed by a first plurality of parallel conductive lines oriented in a first direction 505 and a first plurality of parallel conductive lines oriented in a second direction 510 that are disposed on a side of a transparent substrate (e.g., transparent substrate 410).
  • a transparent substrate e.g., transparent substrate 410
  • the number of parallel conductive lines oriented in the first direction 505 and/or the number of parallel conductive lines oriented in the second direction 510 may or may not be the same and may vary based on an application or design.
  • first conductive pattern 420 may vary based on an application or a design.
  • first conductive pattern 420 may include any other shape or pattern formed by one or more conductive lines or features (not independently illustrated).
  • first conductive pattern 420 is not limited to parallel conductive lines and may comprise any one or more of a predetermined orientation of line segments, a random orientation of line segments, curved line segments, conductive particles, polygons, or any other shape(s) or pattern(s) comprised of electrically conductive material (not independently illustrated) in accordance with one or more embodiments of the present invention.
  • the first plurality of parallel conductive lines oriented in the first direction 505 may be perpendicular (not shown) to the first plurality of parallel conductive lines oriented in the second direction 510, thereby forming a rectangle-type mesh (not shown).
  • the first plurality of parallel conductive lines oriented in the first direction 505 may be angled relative to the first plurality of parallel conductive lines oriented in the second direction 510, thereby forming a parallelogram-type mesh.
  • first direction 505 the relative angle between the first plurality of parallel conductive lines oriented in the first direction 505 and the first plurality of parallel conductive lines oriented in the second direction 510 may vary based on an application or a design in accordance with one or more embodiments of the present invention.
  • a first plurality of channel breaks 515 may partition first conductive pattern 420 into a plurality of column channels 310, each electrically isolated from the others (no electrical continuity).
  • Each column channel 310 may route to a channel pad 540.
  • Each channel pad 540 may route via one or more interconnect conductive lines 550 to an interface connector 560.
  • Interface connectors 560 may provide a connection interface between a touch sensor (e.g., 130 of Figure 2) and a controller (e.g., 210 of Figure 2).
  • FIG. 5B shows a second conductive pattern 430 disposed on a transparent substrate (e.g., transparent substrate 410) in accordance with one or more embodiments of the present invention.
  • second conductive pattern 430 may include a mesh formed by a second plurality of parallel conductive lines oriented in a first direction 520 and a second plurality of parallel conductive lines oriented in a second direction 525 that are disposed on a side of a transparent substrate (e.g., transparent substrate 410).
  • a transparent substrate e.g., transparent substrate 410
  • the second conductive pattern 430 may be substantially similar in size to the first conductive pattern 420.
  • a size of the second conductive pattern 430 may vary based on an application or a design.
  • second conductive pattern 430 may include any other shape or pattern formed by one or more conductive lines or features (not independently illustrated).
  • second conductive pattern 430 is not limited to parallel conductive lines and could be any one or more of a predetermined orientation of line segments, a random orientation of line segments, curved line segments, conductive particles, polygons, or any other shape(s) or pattern(s) comprised of electrically conductive material (not independently illustrated) in accordance with one or more embodiments of the present invention.
  • the second plurality of parallel conductive lines oriented in the first direction 520 may be perpendicular (not shown) to the second plurality of parallel conductive lines oriented in the second direction 525, thereby forming a rectangle-type mesh (not shown).
  • the second plurality of parallel conductive lines oriented in the first direction 520 may be angled relative to the second plurality of parallel conductive lines oriented in the second direction 525, thereby forming a parallelogram-type mesh.
  • the relative angle between the second plurality of parallel conductive lines oriented in the first direction 520 and the second plurality of parallel conductive lines oriented in the second direction 525 may vary based on an application or a design in accordance with one or more embodiments of the present invention.
  • a plurality of channel breaks 530 may partition second conductive pattern 430 into a plurality of row channels 320, each electrically isolated from the others (no electrical continuity).
  • Each row channel 320 may route to a channel pad 540.
  • Each channel pad 540 may route via one or more interconnect conductive lines 550 to an interface connector 560.
  • Interface connectors 560 may provide a connection interface between a touch sensor (e.g., 130 of Figure 2) and a controller (e.g., 210 of Figure 2).
  • FIG. 5C shows a mesh area of a touch sensor 130 in accordance with one or more embodiments of the present invention.
  • a touch sensor 130 may be formed, for example, by disposing a first conductive pattern 420 on a top, or user- facing, side of a transparent substrate (e.g., transparent substrate 410) and disposing a second conductive pattern 430 on a bottom side of the transparent substrate (e.g., transparent substrate 410).
  • a touch sensor 130 may be formed, for example, by disposing a first conductive pattern 420 on a side of a first transparent substrate (e.g., transparent substrate 410), disposing a second conductive pattern 430 on a side of a second transparent substrate (e.g., transparent substrate 410), and bonding the first transparent substrate to the second transparent substrate.
  • a first transparent substrate e.g., transparent substrate 410
  • a second transparent substrate e.g., transparent substrate 410
  • the disposition of the conductive pattern or patterns may vary based on the touch sensor 130 stack up in accordance with one or more embodiments of the present invention.
  • the first conductive pattern 420 and the second conductive pattern 430 may be offset vertically, horizontally, and/or angularly relative to one another.
  • the offset between the first conductive pattern 420 and the second conductive pattern 430 may vary based on an application or a design.
  • One of ordinary skill in the art will recognize that the first conductive pattern 420 and the second conductive pattern 430 may be disposed on substrate or substrates 410 using any process or processes suitable for disposing the conductive patterns on the substrate or substrates 410 in accordance with one or more embodiments of the present invention.
  • the first conductive pattern 420 may include a first plurality of parallel conductive lines oriented in a first direction (e.g., 505 of Figure 5A) and a first plurality of parallel conductive lines oriented in a second direction (e.g., 510 of Figure 5A) that form a mesh that is partitioned by a first plurality of channel breaks (e.g., 515 of Figure 5A) into electrically partitioned column channels 310.
  • a first plurality of parallel conductive lines oriented in a first direction e.g., 505 of Figure 5A
  • a first plurality of parallel conductive lines oriented in a second direction e.g., 510 of Figure 5A
  • the second conductive pattern 430 may include a second plurality of parallel conductive lines oriented in a first direction (e.g., 520 of Figure 5B) and a second plurality of parallel conductive lines oriented in a second direction (e.g., 525 of Figure 5B) that form a mesh that is partitioned by a second plurality of channel breaks (e.g., 530 of Figure 5B) into electrically partitioned row channels 320.
  • a controller e.g., 210 of Figure 2
  • the disposition and/or the role of the first conductive pattern 420 and the second conductive pattern 430 may be reversed.
  • one or more of the plurality of parallel conductive lines oriented in the first direction may have a line width that varies based on an application or design, including, for example, nanometer or micrometer-fine line widths.
  • the number of parallel conductive lines oriented in the first direction (e.g., 505 of Figure 5A, 520 of Figure 5B), the number of parallel conductive lines oriented in the second direction (e.g., 510 of Figure 5A, 525 of Figure 5B), and the line-to-line spacing between them may vary based on an application or a design.
  • the size, configuration, and design of each conductive pattern 420, 430 may vary based on an application or a design in accordance with one or more embodiments of the present invention.
  • touch sensor 130 depicted in Figure 5C is illustrative but not limiting and that the size, shape, and design of the touch sensor 130 is such that there is substantial transmission of an image (not shown) of an underlying display device (e.g., 110 of Figure 1) in actual use that is not shown in the drawing.
  • a cross-link is a bond, covalent or ionic, that links one monomer or polymer to another.
  • Cross-linked polymer structures are linked together in a three-dimensional structure that increases the intermolecular forces, usually covalent bonds, within the polymer chains and limits polymeric chain relaxation.
  • the scratch resistance of a cross-linked polymer may be dictated by the cross-linking density.
  • the cross- linking density refers to the percentage of cross-linked bonds within a given polymer.
  • cross-linked polymer structures provide improved scratch resistance over linear polymer structures
  • the use of conventional coatings based on cross- linked polymer structures presents a number of issues that impede their effective use.
  • Conventional coating compositions typically require a choice, or at least a compromise, between flexibility and hardness. In applications or designs that require a high degree of hardness for scratch resistance, the applied coating tends to be inflexible, brittle, and susceptible to breakage. Alternatively, in applications or designs that require a high degree of flexibility to resist breakage, the applied coating is prone to scratching.
  • conventional coating compositions typically exhibit shrinkage after curing by, for example, exposure to radiation.
  • UV-curable coating compositions containing a (meth)acrylate compound as a principal resin, have been used as protective films because the cured coating provides some manner of transparency, mechanical strength, and scratch resistance.
  • UV-curable coating compositions are composed of a cation radiation curable resin and a cation polymerization initiator which generates a cation when irradiated with UV radiation.
  • inorganic particles are included to increase the mechanical strength, pencil hardness, and scratch resistance.
  • radical-polymerization coating compositions have received less attention because they are difficult to process and cure.
  • UV-curable coating compositions based on radical-polymerization mechanisms
  • a number of issues continue to impede their widespread adoption and use.
  • conventional UV-curable coating compositions based on radical- polymerization possess high internal stress due to the fast curing process and the high internal stress leads to lack of flexibility.
  • a radiation-curable hard-coat composition provides a transparent hard coat that provides well-balanced flexibility and hardness, a high degree of scratch and abrasion resistance, and improved adhesiveness, UV stability, and process-ability in a manufacturing environment, including, for example, touch sensor applications.
  • the radiation-curable hard-coat composition facilitates all aspects of manufacturing including application, processing, and post-fabrication processing and improves yield while reducing costs.
  • a radiation-curable hard-coat composition is a coating that, when cured by radiation, forms a three- dimensional cross-linked network through a free-radical polymerization mechanism.
  • the radiation-curable hard-coat composition includes a principal resin that includes multi-(meth)acrylate functionalized oligomers or polymers and a free radical- polymerization initiator, as a curing agent, that generates a highly reactive species when exposed to radiation.
  • the photo-initiators contains multiple components including at least two curing agents in a predetermined ratio, such as, for example, one or more surface curing agents and one or more deep curing agents that improve curing efficiency and provide homogenous curing along the depth of the applied coating.
  • a solvent may optionally be included that enables the manufacture of the radiation-curable hard-coat composition in a manner that is fast, efficient, and cost effective to apply, process, and process post-fabrication.
  • a multi-(meth)acrylate functionalized oligomers or polymers resin may be used as a film-forming component, which imparts the basic properties of the cured coating.
  • oligomers or polymers are relatively large molecules which are obtained by chemically linking tens to thousands of relatively small molecules.
  • multi-(meth)acrylate functionalized oligomers or polymers typically have a molecular weight in a range between 500 and 20,000 and possess between 2 and 15 acrylate functional groups per molecule. As a result, a high degree of cross-linking may be achieved for improved hardness.
  • the multi-(meth)acrylate functionalized oligomers or polymers may be derived from various chemical backbones, such as, for example, polyol, polyester, polyurethane, polyether, epoxies, and acrylics. In terms of molecular geometry, they may be linear or branched. Because of the skeleton of the resin backbone and the molecular geometry, these multi-(meth)acrylate functionalized oligomers or polymers are highly viscous liquids with a viscosity in a range between at least a few thousand centipoises and potentially greater than one million centipoises in a broad temperature window.
  • Pentaerithritol tetraacrylate("PETA”) is a commonly used UV-curable resin because it provides a high degree of cross-linking in the cured coating due to the relatively large ratio of (meth)acrylate functionality over the molecular weight. As such, it has been employed for protective coatings in various applications, including display applications where it provides a high degree of scratch resistance.
  • PETA resins exhibit significant volumetric shrinkage during curing due to its intrinsic molecular structure. This presents a number of issues including, for example, a high degree of undesirable curling and brittleness.
  • a radiation-curable hard-coat composition that includes multi-(meth)acrylate functionalized oligomers or polymers as a principal resin may use a limited amount of PETA, if it uses any at all, as a complimentary component to provide additional cross-linking density. Because of the unique molecular characteristics noted herein, the multi-(meth)acrylate functionalized oligomers or polymers exhibit a substantially smaller amount of shrinkage, less than 5 percent by volume, after radiation curing. As such, a low level of built-in stress is induced in the coating resulting in a small curling angle after radiation curing.
  • the cross-linking density is very high after curing.
  • the principal resin content as a percentage of weight of the composition may be in a range between 5 percent and 96 percent.
  • the cross-linking density of cross-linked polymers may be dictated by the effectiveness of the radiation curing.
  • photo-initiators play a critically important role in a radiation-curable coating composition.
  • a photo initiator is a compound especially added to a composition to convert absorbed light energy, UV radiation or visible light, or other radiation into chemical energy in the form of an initiating species, such as, for example, free radicals.
  • the free radical- polymerization initiator of the radiation-curable hard-coat composition includes at least two photo-initiators that generate a free radical when irradiated with radiation to initiate polymerization.
  • the photo-initiators may include, but are not limited to, acetophenone, anisoin, anthraquinone, anthraquinone-2-sulfonic acid, sodium salt monohydrate, (benzene) tricarbonylchromium, benzil, benzoin, benzoin ethyl ether, benzoin isobutyl ether, benzoin methyl ether, benzophenone, benzophenone/1- hydroxycyclohexyl phenyl ketone, 50/50 blend, 3,3',4,4'- benzophenonetetracarboxylic dianhydride, 4-benzoylbiphenyl, 2-benzyl-2- (dimethylamino)-4'-morpholinobutyrophenone, 4,4'- bis(diethylamino)benzophenone, 4,4'-bis(dimethylamino)benzophenone, camphor quinone, 2-chlorothioxanthen-9-one,
  • FIG. 6 shows common commercially-available UV lamps and their spectral outputs in accordance with one or more embodiments of the present invention.
  • the H Lamp represents the conventional medium pressure mercury electrode -type lamp output (below 350 nanometers) while the V Lamp represents a significant shift to the visible region (above 400 nanometers).
  • the D Lamp exhibits characteristics of both the H Lamp and the V Lamp. From a curing perspective, the D Lamp is often used to achieve a good curing depth while the H+ Lamp exhibits enhanced emission and shorter wavelengths, effective in promoting surface curing.
  • the photo-initiator is an essential ingredient of radiation-curable coatings and has to have as much absorption as possible in the 200 nanometer to 480 nanometer range, in addition to other characteristics such as high reactivity and high thermal stability.
  • any single photo initiator is not sufficient to cover a sufficiently broad spectrum range that provides sufficient energy absorption for efficient curing under a minimal irradiation dose.
  • a combination of at least two photo-initiators such as, for example, one for deep curing and another for surface curing, may be used to cover a larger or even the full radiation spectrum and provide efficient curing under a minimal irradiation dose.
  • the free radical-polymerization initiator content as a percentage of weight of the composition may be in a range between 0.5 percent and 8.0 percent, preferably in a range between 2.0 percent and 5.0 percent. Due to the spectral interference between different photo-initiators, the ratio of at least two combined photo-initiators has been quantitatively investigated and optimized with an overall photo-initiator content of 4.5 percent by weight of the composition. The samples were measured for curing characteristics in photo-assisted Differential Scanning Calorimetry ("DSC") using DSC-Q2000 by TA Instruments. Light from a 100-W high pressure mercury lamp was used.
  • DSC Differential Scanning Calorimetry
  • the light intensity was determined by placing an empty DSC pan on the sample cell.
  • the light intensity was 80 mW/cm 2 over a wavelength range between 320 nanometers and 500 nanometers.
  • Photopolymerization was carried out at 25° C in a nitrogen atmosphere.
  • Figure 7 shows the photo-initiation efficiency of a radiation-curable hard-coat composition with different free radical-polymerization initiator content (multi- constituent photo-initiator) in accordance with one or more embodiments of the present invention.
  • plot A a radiation-curable hard-coat composition with free radical-polymerization initiator content of 4.5 percent by weight of the composition using only 1 -hydroxy cyclohexyl phenyl ketone is shown.
  • a radiation- curable hard-coat composition with free radical-polymerization initiator content of 4.5 percent by weight of the composition using a combination of 1- hydroxycyclohexyl phenyl ketone and diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide in a ratio of 2 to 1 by weight is shown.
  • a radiation-curable hard- coat composition with free radical-polymerization initiator content of 4.5 percent by weight of the composition using a combination of 1 -hydroxy cyclohexyl phenyl ketone and diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide in a ratio of 3 to 1 by weight is shown.
  • plot D a radiation-curable hard-coat composition with free radical-polymerization initiator content of 4.5 percent by weight of the composition using a combination of 1 -hydroxy cyclohexyl phenyl ketone and diphenyl(2,4,6- trimethylbenzoyl)phosphine oxide in a ratio of 4 to 1 by weight is shown.
  • These plots show the enthalpy value and the curing time of the representative coating compositions. As shown in plot A, approximately 35 percent of the photo- initiator was consumed in the first irradiation cycle (0.6 seconds for each irradiation cycle) and two additional irradiation cycles were needed to initiate the curing agent up to 90 percent.
  • cross-linked polymer materials typically cannot be directly applied or coated onto a substrate or screen through a solution-based application process because the cross-linked polymers are not dissolvable in any solvent and only swell when placed in the solvent.
  • Coating compositions are typically provided in the liquid state to allow the molecules to move and react more efficiently.
  • a solvent is employed in the coating compositions to provide a cost-effective solution process and other property adjustments including viscosity.
  • the solvent is an important component of the coating composition as it plays a critically important role in determining viscosity, film thickness, coating quality, and baking process parameters for effective solvent removal.
  • the solvent content may depend on the coating method used, the desired coating thickness, and the properties of the finished coating product.
  • the coating composition may contain solid content in a range between 10 percent by weight and 80 percent by weight of the composition, and in some applications, solvent content in a range between 20 percent by weight and 30 percent by weight of the composition to regulate viscosity.
  • radiation-curable hard-coat composition that includes a principal resin of multi-end-capped (meth)acrylate functionalized oligomers or polymers have a large molecular weight in a range between 500 and 20,000 and between 2 and 15 acrylate functional groups per molecule. When put in a solvent, the oligomers and polymers may potentially aggregate in micro scale due to the entanglement of random-coil chains of polymers.
  • a desirable solvent for the radiation-curable hard-coat composition includes the ability to dissolve coating resins under acceptable conditions for production, provide suitable coating quality, provide acceptable tolerance for manufacturing to a target film thickness based on the slope of viscosity versus solid content, and fast drying rate to ensure complete evaporation of solvent during the soft-bake phase.
  • the soft-bake phase is the physical process between the deposition of the coating on a substrate and radiation curing in which a liquid-cast resin is converted to a relative solid film through solvent evaporation.
  • a temperature controlled oven channel may be employed to ensure the complete elimination of added solvents because any residual solvent may adversely affect the curing and the scratch resistance properties of the coating.
  • solvents that may optionally be used in the radiation-curable hard-coat composition may include, but are not limited to, ketone -type solvents (both acyclic ketones and cyclic ketones), such as acetone, methyl ethyl ketone, iso-butyl ethyl ketone and cyclopentanone, cyclohexanone, as well as alcohol-type solvents such as ethoxy ethanol, methoxy ethanol, and l-methoxy-2-propanol.
  • ketone -type solvents both acyclic ketones and cyclic ketones
  • alcohol-type solvents such as ethoxy ethanol, methoxy ethanol, and l-methoxy-2-propanol.
  • the reduction of trapped air bubbles improves cross-linking induced during radiation curing. Air bubbles tend to contain approximately 21 percent oxygen by volume and the oxygen tends to quench the free radicals.
  • co-solvents of two or more solvents may be applied as the coating carrier.
  • the large variety of solvents enables flexibility in tuning the viscosity of the radiation-curable hard-coat composition for various coating techniques including, for example, inkjet printing, spray coating, slot-die coating, dip-coating, curtain coating, gravure coating, and reverse-gravure coating.
  • coating techniques including, for example, inkjet printing, spray coating, slot-die coating, dip-coating, curtain coating, gravure coating, and reverse-gravure coating.
  • various combinations of the above-noted components may be used to create a radiation-curable hard-coat composition that exhibit different degrees of the various characteristics of the coating composition. While a few exemplary combinations are provided herein, one of ordinary skill in the art, having the benefit of this disclosure, will recognize that other combinations may be used in accordance with one or more embodiments of the present invention.
  • a radiation-curable hard coat composition may include a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers and a free radical-polymerization initiator comprising at least two photo-initiators in a predetermined ratio that generate a highly reactive species when irradiated with radiation.
  • the principal resin may comprise aliphatic urethane acrylate content in a range between 5 percent and 90 percent as a percentage of weight of the composition and PETA content in a range between 0 percent and 70 percent as a percentage of weight of the composition.
  • the free radical- polymerization initiator may comprise initiator content in a range between 1 percent and 5 percent as a percentage of weight of the composition to absorb shorter wavelengths, that has maximum absorption in a range between 200 nanometers and 300 nanometers such as, for example, 1 -hydroxy cyclohexyl phenyl ketone, and initiator content in a range between 0.5 percent and 4 percent as a percentage of weight of the composition to absorb longer wavelengths, that has absorption in a range between 300 nanometers and 420 nanometers, such as, for example, diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide, where for the examples given, the predetermined ration is 4-to-l .
  • the predetermined ratio of the first initiator to the second initiator is in a range between 5-to-l and 2-to-l .
  • a solvent comprising l-methoxy-2-propanol content in a range between 10 percent and 80 percent as a percentage of weight of the composition.
  • the coating composition was deposited on PMMA and PET substrates followed by UV radiation curing to achieve hard-coat films with a thickness ranging from 5 micrometers to 20 micrometers.
  • the applied hard coat exhibited high pencil hardness (8H to 9H for PMMA substrate and 4H to 6H for PET substrate) with a loading of 750 grams based on ASTM D-3363 test, excellent abrasion resistance with no obvious scratch after 1000 cycles of steel-wool test with a loading of 750 grams based on ASTM F-2357 test, and excellent adhesion of 5B based on ASTM D-3359 test.
  • a radiation-curable hard coat composition may include a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers and a free radical-polymerization initiator comprising at least two photo- initiators in a predetermined ratio that generate a highly reactive species when irradiated with radiation.
  • the principal resin may comprise a hyperbranched polyester acrylate oligomer content in a range between 5 percent and 96 percent as a percentage of weight of the composition and PETA content in a range between 0 percent and 70 percent as a percentage of weight of the composition.
  • the free radical-polymerization initiator may comprise initiator content in a range between 1 percent and 5 percent as a percentage of weight of the composition to absorb shorter wavelengths, that has maximum absorption in a range between 200 nanometers and 300 nanometers such as, for example, 1 -hydroxy cyclohexyl phenyl ketone and initiator content in a range between 0.5 percent and 4 percent as a percentage of weight of the composition to absorb longer wavelengths, that has absorption in a range between 300 nanometers and 420 nanometers, such as, for example, diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide, where for the examples given, the predetermined ration is 4-to-l .
  • the predetermined ratio of the first initiator to the second initiator is in a range between 5-to-l and 2-to-l .
  • a solvent comprising l-methoxy-2-propanol content in a range between 10 percent and 80 percent as a percentage of weight of the composition.
  • the coating composition was deposited on PMMA and PET substrates followed by UV radiation curing to achieve hard-coat films with a thickness ranging from 5 micrometers to 20 micrometers.
  • the applied hard coat exhibited high pencil hardness (8H to 9H for PMMA substrate and 4H to 6H for PET substrate) with a loading of 750 grams based on ASTM D-3363 test, excellent abrasion resistance with no obvious scratch after 1000 cycles of steel-wool test with a loading of 750 grams based on ASTM F-2357 test, and excellent adhesion of 5B based on ASTM D-3359 test.
  • a radiation-curable hard coat composition may include a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers and a free radical-polymerization initiator comprising at least two photo-initiators in a predetermined ratio that generate a highly reactive species when irradiated with radiation.
  • the principal resin may comprise aliphatic urethane acrylate content in a range between 5 percent and 90 percent as a percentage of weight of the composition and PETA content in a range between 0 percent and 70 percent as a percentage of weight of the composition.
  • the free radical- polymerization initiator may comprise 1 -hydroxy cyclohexyl phenyl ketone content and diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide content in a 1-to-l ratio where each constitutes in a range between 1 percent and 4 percent as a percentage of weight of the composition.
  • the predetermined ratio of the first initiator to the second initiator is in a range between 5-to-l and 2-to-l .
  • a solvent comprising l-methoxy-2-propanol content in a range between 10 percent and 80 percent as a percentage of weight of the composition.
  • the coating composition was deposited on PMMA and PET substrates followed by UV radiation curing to achieve hard-coat films with a thickness ranging from 5 micrometers to 20 micrometers.
  • the applied hard coat exhibited high pencil hardness (4H to 7H for PMMA substrate and 2H to 4H for PET substrate) with a loading of 750 grams based on ASTM D-3363 test, excellent abrasion resistance with no obvious scratch after 1000 cycles of steel-wool test with a loading of 750 grams based on ASTM F-2357 test, and excellent adhesion of 5B based on ASTM D-3359 test.
  • Advantages of one or more embodiments of the present invention may include one or more of the following:
  • a radiation-curable hard-coat composition provides a hard-coat that is easy to apply, cures efficiently in a single UV irradiation cycle, provides improved flexibility and hardness, and provides improved process-ability for use in a manufacturing environment.
  • a radiation-curable hard-coat composition provides improved flexibility while maintaining a high degree of hardness and scratch and abrasion resistance.
  • a radiation-curable hard-coat composition reduces fragility and brittleness that reduces or eliminates undesirable breakage, cracking, and other failure modes that occur in post- fabrication processing of substrates with applied coatings.
  • a radiation-curable hard-coat composition reduces curling by lowering the built-in stress that significantly reduces the curling angle when the coating is applied to substrates with low mechanical strength, such as, for example, flexible PET substrates used in touch sensor applications.
  • a radiation-curable hard-coat composition includes a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers.
  • a radiation-curable hard-coat composition includes a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers that may be derived from various chemical backbones including, for example, polyol, polyester, polyurethane, polyether, epoxies, and acrylics.
  • a radiation-curable hard-coat composition includes a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers that may be linear or branched. Because of the skeleton of the resin backbone and the molecular geometry, these multi- (meth)acrylate functionalized oligomers or polymers are highly viscous in the liquid state.
  • a radiation-curable hard-coat composition includes a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers that, after curing, form a hard and rigid polymer with high tensile strength and modulus.
  • a radiation-curable hard-coat composition includes a principal resin comprising multi-(meth)acrylate functionalized oligomers or polymers that, after curing, exhibit a comparatively small shrinkage in volume that induces a low level of built-in stress and reduces the curling angle of the applied coating.
  • a radiation-curable hard-coat composition includes a multi-constituent photo-initiator comprised of at least two different photo-initiators.
  • a radiation-curable hard-coat composition includes a multi-constituent photo-initiator comprised of one or more surface curing agents and one or more deep curing agents that improve curing efficiency and provide homogenous curing along the depth of the applied coating
  • a radiation-curable hard-coat composition includes a multi-constituent photo-initiator that provides substantial absorption in a range between 200 nanometer and 480 nanometers.
  • a radiation-curable hard-coat composition includes a multi-constituent photo-initiator that minimizes spectral interference.
  • a radiation-curable hard-coat composition includes a multi-constituent photo-initiator that provides a high degree of photo-initiation efficiency in a single irradiation cycle.
  • a radiation-curable hard-coat composition includes a multi-constituent photo-initiator that allows for a high coating speed of up to 200 feet per minute in a high volume manufacturing environment with low defects, high yield, and excellent coating performance.
  • a radiation-curable hard-coat composition includes a solvent or co-solvents that prevent aggregation of the multi-(meth)acrylate functionalized oligomers or polymers in the micro scale.
  • a radiation-curable hard-coat composition includes a solvent or co-solvents that reduces or eliminates air bubbles that quench free radicals and reduce the optical performance of the coating.
  • a radiation-curable hard-coat composition provides improved optical performance including high transmission yield and low haze.
  • a radiation-curable hard-coat composition may be effectively applied using spray coating, slot-die coating, dip-coating, and reverse-gravure coating techniques.

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Abstract

Selon l'invention, une composition de revêtement dur durcissable par rayonnement comporte une résine principale comprenant des oligomères ou polymères multi(méth)acrylate fonctionnalisés et un initiateur de polymérisation radicalaire. L'initiateur comprend, selon une proportion prédéterminée, au moins deux photo-initiateurs qui génèrent une espèce hautement réactive lorsqu'elle est irradiée par un rayonnement.
PCT/US2015/033619 2014-04-25 2015-06-01 Composition de revêtement dur durcissable par rayonnement WO2016007239A1 (fr)

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