Coatings Having Filler-Polymer Compositions with Combined Low Dielectric Constant, High Resistivity, and Optical Density Properties and Controlled Electrical Resistivity, Devices Made Therewith, and Methods for Making Same

Patent metadata

Field	Value
Publication number	US-2016017168-A1
Application number	US-201414771846-A
Country	US
Kind code	A1
Filing date	Mar 12, 2014
Priority date	Mar 13, 2013
Publication date	Jan 21, 2016
Grant date	—

Abstract

UV curable coatings containing dual phase filler-polymer compositions with high resistivity, low dielectric constant, good optical density, and controlled electrical resistivity are described, and cured coatings or films formed thereof, along with their use in black matrix, black column spacers, and other light shielding coating elements in LCD. Devices having these black matrices, black column spacers, and/or other light shielding coating elements, and methods of preparing and making these various materials and products are also described.

First claim

What is claimed is:

1 . A UV-curable coating comprising a filler-polymer composition comprising:
at least one polymer and at least one filler, said filler comprising: a) a controlled amount of a dual phase filler having a silica phase and a carbon phase, or b) a dual phase filler having a silica phase and a carbon phase, wherein said silica phase is a controlled surface coverage amount of the silica phase, or c) a dual phase filler having a silica phase and a carbon phase, wherein said dual phase filler has a controlled morphology; or d) any combination of a), b), and c).

2 . The coating of claim 1 , wherein the coating, after curing, is a black matrix.

3 . The coating of claim 1 , wherein the coating, after curing, is a black column spacer.

4 . The coating of claim 1 , wherein the coating, after curing, is a component of a light shielding coating element in an LCD device.

5 . The coating of claim 1 , wherein the dual phase filler comprises fused primary particles with an average aggregate size of less than 250 nm and an average primary particle size of 50 nm or less.

6 . The coating of claim 1 , wherein dual phase filler has less than 1% weight loss when subjected to the temperature from 120° C. up to 450° C. in air with a temperature ramp of 5 deg C. per minute.

7 . The coating of claim 1 , wherein said electrical resistivity of said filler-polymer composition is maintained upon thermal processing or post-processing of said filler-polymer composition at temperatures up to thermal stability of said at least one polymer.

8 . The coating of claim 1 , wherein said controlled amount is an amount selected from 1 wt % filler loading to 40 wt % filler loading.

9 . The coating of claim 1 , wherein the coating has a surface resistivity of 10 6 to 10 16 Ohm/sq

10 . The coating of claim 1 , wherein the coating has a surface resistivity of 10 12 to 10 16 Ohm/sq.

11 . The coating of claim 1 , wherein said controlled surface coverage amount of the silica phase is from about 50% to about 99%, and wherein a higher controlled surface coverage amount provides a higher electrical resistivity in said coating.

12 . The coating of claim 1 , wherein the coating has a dielectric constant of less than 20.

13 . The coating of claim 1 , wherein the coating has an optical density of at least about 1 or more measured at a thickness of about 1 micron.

14 . The coating of claim 1 , wherein said silica phase is present in an amount of 10 wt % to about 90 wt % based on the weight of the dual phase filler.

15 . The coating of claim 1 , wherein said dual phase filler has attached at least one chemical group.

16 . The coating of claim 1 , wherein said dual phase filler has attached at least one silane.

17 . A UV-curable coating comprising a polymer composition which comprises at least one polymer and a dual phase filler having a silica phase and a carbon phase, wherein said dual phase filler has an exposed outer surface area, and said silica phase comprises from about 50% to about 99% by surface area of said exposed outer surface area, wherein the coating has a resistivity of 10 10 to 10 16 Ohm/sq, a dielectric constant of less than 20, and an optical density of at least about 1 or more at a thickness of about 1 micron.

18 . The coating of claim 17 , wherein the coating, after curing, is a black matrix.

19 . The coating of claim 17 , wherein the coating, after curing, is a black column spacer.

20 . The coating of claim 17 , wherein the coating, after curing, is a component of a light shielding element in an LCD device.

21 . The coating of claim 17 , wherein said silica phase is 50% to 90% by surface area of said exposed outer surface area.

22 . The coating of claim 17 , wherein said silica phase is 50% to 80% by surface area of said exposed outer surface area.

23 . The coating of claim 17 , wherein said silica phase is 50% to 70% by surface area of said exposed outer surface area.

24 . The coating of claim 17 , wherein said polymer is at least one curable polymer.

25 . The coating of claim 17 , wherein said dual phase filler has attached at least one chemical group.

26 . The coating of claim 25 , wherein said at least one chemical group is a silane.

27 . The coating of claim 17 , wherein said dual phase filler has an OAN of 50 to 140 cc/100 g filler.

28 . The coating of claim 17 , wherein said dual phase filler has an OAN of 141 to 200 cc/100 g filler.

29 . A UV-curable coating comprising a polymer composition which comprises:
a) at least one polymer; and b) at least one dual phase filler having an exposed outer surface area, wherein said dual phase filler has an OAN between 50 cc/100 g to 200 cc/100 g filler, a silica content of 10 wt % to 90 wt %, and said silica phase comprises from about 50% to about 99% by surface area of said exposed outer surface area.

30 . The coating of claim 29 , wherein the coating, after curing, is a black matrix.

31 . The coating of claim 29 , wherein the coating, after curing, is a black column spacer.

32 . The coating of claim 29 , wherein the coating, after curing, is a component of a light shielding element in LCD device.

33 . The coating of claim 29 , wherein the polymer composition comprises a cured composition.

34 . The coating of claim 29 , wherein the coating has a surface resistivity of 10 10 to 10 16 Ohm/sq.

35 . The coating of claim 29 , wherein the coating has a dielectric constant of less than 20.

36 . The coating of claim 29 , wherein the coating has an optical density of at least about 1 or more at a thickness of about 1 micron.

37 . A UV-curable coating comprising:
a) at least one UV-curable polymer; and b) at least one dual phase filler having an exposed outer surface area, wherein said dual phase filler has an OAN from about 50 to about 200 cc/100 g filler, a silica content of 10 wt % to 90 wt %, and said silica phase comprises from about 50% to about 99% by surface area of said exposed outer surface area, where the electrical surface resistivity changes an order of magnitude of 2 or less over loading levels from 5 wt % to 35 wt % in the polymer composition.

38 . The coating of claim 37 , wherein the coating, after curing, is a black matrix.

39 . The coating of claim 37 , wherein the coating, after curing, is a black column spacer.

40 . The coating of claim 37 , wherein the coating, after curing, is a component of a light shielding element in LCD device.

41 . The coating of claim 37 , wherein the electrical resistivity of said polymer composition and electrical resistivity of a polymer composition with said at least one polymer without any filler changes an order of magnitude 2 or less over said loading levels.

42 . A liquid crystal device comprising the UV-curable coating of any of claims 1 , 17 , 29 , or 37 .

43 . A black matrix comprising a cured coating of any of claims 1 , 17 , 29 , or 37 .

44 . A black column spacer comprising a cured coating of any of claims 1 , 17 , 29 , or 37 .

45 . A

Assignees

• Cabot Corp

Inventors

• Korchev Andriy
• Huffman Jeremy K
• Kyrlidis Agathagelos
• Kossyrev Pavel A
• Step Eugene N
• Moeser Geoffrey D
• Zhang Qingling

Classifications

• C09D7/00

  Features of coating compositions, not provided for in group C09D5/00 (driers C09F9/00); Processes for incorporating ingredients in coating compositions · CPC title

• C08K3/04

  Carbon · CPC title

• C08K3/36

  Silica · CPC title

• C09D5/00 Primary

  Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced {(electrically insulating plastics, resins or waxes H01B3/30)}; Filling pastes · CPC title

• C09D133/06 Primary

  of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical · CPC title