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Claims  |
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What is claimed is:
1. A conductive substrate having on the surface thereof a transparent
conductive coating formed from a coating solution for forming a
transparent conductive coating comprising conductive particles having:
(a) an average particle diameter of not more than 500 .ANG., and
(b) an amount of said particles having a particle diameter of not more than
600 .ANG. being not less than 60% by weight,
(c) an amount of said particles having a particle diameter of not more than
100 .ANG. being not less than 5% by weight,
(d) an amount of said particles having a particle diameter of not less than
1000 .ANG. being not more that 15% by weight, and a matrix consisting of a
silica polymer having
(A) an average degree of polymerization of 1,500-10,000, and
(B) an amount of said polymer having a degree of polymerization of not more
than 3,000 being not more than 50% by weight, and
(C) an amount of said polymer having a degree of polymerization of not less
than 10,000 being not more than 20% by weight.
2. The conductive substrate as claimed in claim 1 wherein a transparent
protective coating is formed on the surface of the transparent conductive
coating.
3. The conductive substrate as claimed in claim 1 or 2 wherein the surface
of the substrate, on which the transparent conductive coating has been
formed, has a surface resistivity of 10.sup.3 to 10.sup.10
.OMEGA./.quadrature., and a haze of not more than 1%.
4. The conductive substrate as claimed in claim 1 or 2 wherein the surface
of the substrate, on which the transparent conductive coating has been
formed, has a surface resistivity of 10.sup.3 to 10.sup.10
.OMEGA./.quadrature., and a glossiness of 40 to 90%.
5. The conductive substrate claimed in claim 2 wherein the surface of the
substrate, on which the transparent conductive coating and transparent
protective coating have been formed, has a surface resistivity of 10.sup.3
to 10.sup.10 .OMEGA./.quadrature., a glossiness of 40 to 90%, and a
surface reflectance of not more than 1%.
6. The conductive substrate as claimed in claim 1 wherein the surface of
the substrate, on which the transparent conductive coating has been
formed, has a surface resistivity of 10.sup.3 to 10.sup.10
.OMEGA./.quadrature., and a haze of not more than 1%.
7. The conductive substrate as claimed in claim 1 wherein the surface of
the substrate, on which the transparent conductive coating has been
formed, has a surface resistivity of 10.sup.3 to 10.sup.10
.OMEGA./.quadrature., and a glossiness of 40 to 90%.
8. A conductive substrate wherein the conductive substrate is a face-plate
of a display panel for a display device, said conductive substrate having
on the surface thereof a transparent conductive coating formed from a
coating solution for forming a transparent conductive coating comprising
conductive particles having:
(a) an average particle diameter of not more than 500 .ANG.,
(b) an amount of said particles having a particle diameter of not more than
600 .ANG. being not less than 60% by weight,
(c) an amount of said particles having a particle diameter of not more than
100 .ANG. being not less than 5% by weight,
(d) an amount of said particles having a particle diameter of not less than
1000 .ANG. being more than 15% by weight, and a matrix consisting of a
silica polymer having:
(A) an average degree of polymerization of 1,500-10,000,
(B) an amount of said polymer having a degree of polymerization of not more
than 3,000 being not more than 50% by weight, and
(C) an amount of said polymer having a degree of polymerization of not less
than 10,000 being not more than 20% by weight.
9. The conductive substrate as claimed in claim 8 wherein a transparent
protective coating is formed on the surface of the transparent conductive
coating.
10. The conductive substrate as claimed in claim 8 or 9 wherein the display
panel, on which the transparent conductive coating has been formed, has a
surface resistivity of 10.sup.3 to 10.sup.10 .OMEGA./.quadrature., a haze
of not more than 1% and a resolving power of more than 70 bar/cm.
11. The conductive substrate as claimed in claim 8 or 9 wherein the display
panel, on which the transparent conductive count has been formed, has a
surface resistance of 10.sup.3 to 10.sup.10 .OMEGA./.quadrature., a
glossiness of 40 to 90%, and a resolving power of more than 60 bar/cm.
12. The conductive substrate as claimed in claim 9 wherein the display
panel, on which the transparent conductive coating and the transparent
protective coating have been formed, has a surface resistivity of 10.sup.3
to 10.sup.10 .OMEGA./.quadrature., a glossiness of 40 to 90%, a surface
reflectance of not more than 1%, and a resolving power of more than 60
bar/cm.
13. The conductive substrate as claimed in claim 8 wherein the display
panel, on which the transparent conductive coating has been formed, has a
surface resistivity of 10.sup.3 to 10.sup.10 .OMEGA./.quadrature., a haze
of not more than 1% and a resolving power of more that 70 bar/cm.
14. The conductive substrate as claimed in claim 8 wherein the display
panel, on which the transparent conductive coating has been formed, has a
surface resistance of 10.sup.3 to 10.sup.10 .OMEGA./.quadrature., a
glossiness of 40 to 90%, and a resolving power of more than 60 bar/cm. |
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Claims  |
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Description  |
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FIELD OF INDUSTRIAL APPLICATION
This invention relates to coating solution for forming transparent
conductive coatings, process for preparing the same, conductive
substrates, processes for preparing the same, and display devices provided
with transparent conductive substrates. More particularly, the invention
relates to a coating solution capable of forming transparent conductive
coatings excellent in adhesion and surface smoothness as well as in
durability such as water resistance and alkali resistance, a process for
preparing said coating solution, conductive substrates on the surface of
which a transparent conductive coating having such excellent properties as
mentioned above has been formed, processes for preparing said conductive
substrates, and display devices provided with transparent conductive
substrates.
TECHNOLOGICAL BACKGROUND
Though glass or plastics are being used as transparent substrates, they are
liable to generate static electricity on the surface thereof, because such
substrates are insulators. When these susbtrates such as glass or plastics
are used for a display panel such as Braun tube (CRT), fluorescent
indication pipe (FIP), plasma display (PDP), or liquid crystal display
(LCD), static electricity is generated on the face-plate of the display
panel and dust or the like is attracted thereto, whereby the displayed
images on the panel becomes difficult to be visible. Particularly, in the
case of LCD, there is sometimes observed destruction of IC or
miss-operation of the display device caused by such static electricity as
generated above.
In an electrophotographic duplicator for ordinary paper (PPC) equipped with
an automatic draft feeder (ADF), when a copy is taken successively from a
plurality of drafts through ADF, a contact glass plate on which the draft
is placed and the draft in the sheet form fed through ADF are rubbed with
each other, whereby static electricity is generated on the contact glass
plate, and by virtue of the static electricity thus generated, the draft
attaches to the contact glass plate and stays thereon, plugging sometimes
the ADF with the drafts.
In order to inhibit the generation of static electricity on the
above-mentioned substrates used for a display panel of the display device
or contact glass plate of PPC, there has heretofore been used to apply a
transparent substrate having thereon a transparent conductive film to the
surface of said display panel or said contact glass plate.
Known hitherto as a technique of obtaining such transparent conductive
substrates as mentioned above is, for example, a method wherein a
transparent conductive film consisting of a metal or inorganic oxide is
formed on the surface of a transparent conductive substrate by means of a
dry process such as CVD, PVD, vacuum evaporation or sputtering, or a
method wherein a conductive coating is formed on the surface of a
substrate by means of a wet process which comprises applying a coating
solution containing a conductive material such as tin oxide and a
transparent matrix-forming component on the surface of a substrate
followed by drying and curing.
In the dry process such as CVD referred to above, however, there are
involved such problems that the film must be formed by a batchwise method
using a vacuum evaporator, and that the surface area or shape of the
substrate on which the film is formed is limited to depending upon the
size of the vacuum evaporator used.
In the wet process mentioned above, on the one hand, there are involved
such problems that the transparent conductive coating formed by using, as
a transparent matrix-forming component, a binder resin such as acrylic
resin, butyral resin, melamine resin or vinyl chloride/vinyl acetate
copolymer resin is poor in transparency, scratch resistance, adhesion to
the substrate or durability such as alkali resistance, acid resistance,
water resistance or solvent resistance.
Recently, with the view of solving such problems as mentioned above, there
have been proposed various coating solutions for forming conductive
coatings and transparent conductive coatings formed by using such coating
solutions for forming conductive coatings.
For example, Japanese Patent L-O-P Publn. No. 193971/1988 proposes
conductive coatings consisting essentially of conductive particles and a
vehicle (matrix), said conductive particles having an average particle
diameter of at least 10 .ANG. and not more than 5 .mu.m.
Japanese Patent L-O-P Publn. No. 22340/1990 proposes molded products
(transparent substrates) having thereon a transparent coating (transparent
conductive coating) containing 5-80% by weight of particulate inorganic
substance consisting of tin oxide having an average particle diameter of
1-300 .mu.m.
In the proposals mentioned above, there are used, as the matrices,
organosilicon compounds represented by the following general formula (A).
R.sup.1.sub.a R.sup.2.sub.b Si(OR.sup.3).sub.4-a-b (A)
By way of Japanese Patent L-O-P Publn. No. 54613/1989, WO89/03114 and
WO90/02157, the present applicant has proposed coating solutions for
forming conductive coatings prepared by mixing conductive substances with
partial hydrolyzates of alkoxysilane and acetylacetonatochelate such as
bisacetylacetonatodialkoxy zirconium as a matrix in a mixed solvent of
water-organic solvent, and substrate having on the surface thereof a
transparent conductive coating obtained from the above mentioned coating
solutions.
These substrates having coated thereon a transparent conductive coating as
obtained above, however, are required to have further improved durability
and also excellent surface smoothness, though said substrates are
excellent in conductivity and transparency and also found to be at least
satisfactory with respect to properties such as durability.
In the case of a display panel with a transparent conductive coating, it is
requested that the quality, especially resolving power, of the images
displayed by means of a display device equipped with the display panel
will not be deteriorated by the presence of said transparent conductive
coating.
The present invention has been made in view of such circumstances as
mentioned above, and the main objects of the invention are to provide
coating solutions capable of forming transparent conductive coatings
excellent in adhesion, surface smoothness and durability such as alkali
resistance and water resistance on the surface of substrates such as
glass, plastics and the like, process for preparing the same, conductive
substrates having formed on the surface thereof transparent conductive
coating having such excellent properties as mentioned above, processes for
preparing the same, and display devices equipped with said transparent
conductive substrates.
DISCLOSURE OF THE INVENTION
The coating solution for forming a transparent conductive coating of the
present invention is characterized by comprising conductive particles
having
(a) an average particle diameter of not more than 500 .ANG., and
(b) an amount of particles having a particle diameter of not more than 600
.ANG. being more than 60% by weight,
(c) an amount of particles having a particle diameter of not more than 100
.ANG. being more than 5% by weight, and
(d) an amount of particles having a particle diameter of more than 1000
.ANG. being not more than 15% by weight, and a matrix comprising a silica
polymer having
(A) an average degree of polymerization of 1,500-10,000, and
(B) an amount of the polymer having a degree of polymerization of not more
than 3,000 being not more than 50% by weight, and
(C) an amount of the polymer having a degree of polymerization of more than
10,000 being not more than 20% by weight.
The coating solution for forming a transparent conductive coating mentioned
above may be prepared by dispersing or dissolving in water and/or organic
solvent conductive particles having specific average particle diameter and
particle size distribution mentioned above obtained by pulverizing and/or
classifying powdered conductive particles or conductive particle dispersed
in a sol and a matrix having the specific degree of polymerization as
defined above.
The conductive substrates of the invention comprises a substrate and a
transparent conductive coating formed from such coating solution for
forming a transparent conductive coating as mentioned above.
The conductive substrate of the invention as mentioned above may be
prepared by applying the above-mentioned coating solution for forming
transparent conductive coatings onto the surface of the substrate,
followed by heat curing.
The above-mentioned conductive substrate may also be prepared favorably by
irradiating the transparent conductive coating as formed and still at an
uncured stage prior to heating with an electromagnetic wave having a
wavelength shorter than that of visible light, or by exposing the
transparent conductive coatings at an uncured stage to a gaseous
atmosphere wherein curing reaction of said conductive coating is
accelerated.
The display device of the invention is characterized in that a display
panel of said display device has a transparent conductive coating as
obtained from the coating solution for forming transparent conductive
coatings mentioned above on the face-plate of a display panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sketch of a bar chart used in the invention for the measurement
of resolving power.
FIG. 2 is an illustration showing how to measure resolving power.
BEST MODE OF THE INVENTION
To begin with, the coating solution for forming a transparent conductive
coating, conductive substrate, and process for the preparation thereof of
the present invention are illustrated below in detail.
I) Coating Solution for Forming a Transparent Conductive Coating
The coating solution of the invention for forming a transparent conductive
coating is a dispersion which comprises a) conductive particles having a
specific average particle diameter and specific particle size distribution
as defined above and b) a specific matrix as mentioned above in a
dispersion medium composed of water and/or organic solvent.
a) Conductive Particles
The conductive particles used in the invention include those known
hitherto, concretely tin oxide, tin oxide doped with Sb, F or P, indium
oxide, indium oxide doped with Sn or F, and antimony oxide.
The conductive particles as mentioned above may be obtained by the method
disclosed in Japanese Patent L-O-P Publication Nos. 230617/1987,
11519/1988 or 221124/1990 filed previously by the present applicant.
The conductive particles used in the invention have an average particle
diameter of not more than 500 .ANG., preferably 50-300 .ANG., and an
amount of particles having a diameter of not more than 600 .ANG. is more
than 60% by weight, preferably more than 80% by weight based on all
transparent conductive particles, an amount of particles having a diameter
of not more than 100 .ANG. is more than 5% by weight, preferably more than
20% by weight based on all transparent conductive particles, and an amount
of particles having a diameter of more than 1000 .ANG. is not more than
15% by weight, preferably not more than 5% by weight based on all
transparent conductive particles.
The conductive particles having such specific average particle diameter and
particle size distribution as defined above may be prepared by pulverizing
and/or classifying such known conductive particles as mentioned above by
means of a suitable means until the average particle diameter and particle
size distribution of said particles satisfactorily fall within the
above-mentioned ranges.
The pulverization and/or classification for controlling the average
particle diameter and powder size distribution of the above-mentioned
conductive particles may be carried out at a stage of either powder or
sol, and may also be carried out either before or after the preparation of
the coating solution for forming a transparent conductive coating.
In the present invention, because the conductive particles having specific
average particle diameter and particle size distribution as defined above
are used for preparing coating solutions for forming a transparent
conductive coating, the resulting coating solutions are found to be
stable, keeping the conductive particles highly dispersed.
b) Matrix
Silica polymers are used as matrices in the coating solution of the present
invention for forming a transparent conductive coating.
The silica polymers mentioned above have an average degree of
polymerization of 1,500-10,000, preferably 2,500-7,500, wherein not more
than 50% by weight, preferably not more than 20% by weight of the polymer
has a degree of polymerization of not more than 3,000, and not more than
20% by weight, preferably not more than 10% by weight of the polymer has a
degree of polymerization of more than 10,000.
By silica polymers as referred to herein are meant polycondensation
products obtained by hydrolysis of organosilicon compounds such as
alkoxysilane.
The organosilicon compounds used therein include concretely one of the
alkoxysilanes represented by the following general formula [I], or a
combinations of two or more said alkoxysilanes.
R.sub.a --Si--(OR').sub.4-a [I]
wherein R is an alkyl group represented by --C.sub.n H.sub.2n+1 (n=1-4),
hydrogen atom or halogen atom, R' is the same alkyl group as defined above
by R or an alkylalkoxy group represented by --C.sub.2 H.sub.4 OC.sub.n
H.sub.2n+1 (n=1-4) or hydrogen atom, and a is an integer of 0-3.
The degree of polymerization as used in the invention signifies the degree
of polymerization in terms of polystyrene as determined by means of gel
chromatography.
The silica polymers used in the invention may be obtained, for example, by
a method wherein the above-mentioned alkoxysilane is subjected to
hydrolysis in the presence of acid, for example, nitric acid, hydrochloric
acid or acetic acid in a mixed solvent such as water-alcohol.
The hydrolysis of the alkoxysilane as mentioned above is carried out
preferably under the conditions where acid/SiO.sub.2 =0.0001-0.05 (wt/wt)
and water/SiO.sub.2 =4-16 (mol/mol) in which SiO.sub.2 represents a value
obtained by converting the alkoxysilane into SiO.sub.2.
The hydrolysis of the alkoxysilane is preferably carried out at a
temperature of from room temperature to 200.degree. C.
Further, a concentration of the alkoxysilane used for the hydrolysis is
preferably about 3-25% by weight in terms of SiO.sub.2, and the
concentration thereof is preferably controlled to be higher when the
hydrolysis temperature becomes lower.
The coating solution for forming a transparent conductive coating may be
prepared by dispersing or dissolving in water and/or organic solvent
conductive particles having specific average particle diameter and
particle size distribution mentioned above and the matrix having the
specific degree of polymerization as defined above.
The preparation of the coating solution is, for example, carried out as
follows:
To a sol in which the conductive particles having the specific particle
size distribution dispersed in the sol, a dispersion of the silica
polymers having the specific degree of polymerization dispersed in
water-alcohol is added in a predetermined amount. A solid content
(conductive particles and silica polymers) of the resulting mixture is
controlled by adding water and/or alcohol.
Then an acid such as hydrochloric acid and nitric acid is added to the
mixture to control a pH of the mixture to 1.5-6.0, preferably 1.5-4.0, to
obtain the coating solution.
The mixing ratio of the conductive particles to the matrix in the coating
solution for forming a transparent conductive coating is preferably as
follows:
EO.sub.x /SiO.sub.2 =0.5-5.0 (wt/wt)
wherein EO.sub.x represents a weight of the conductive particles in terms
of oxides, and SiO.sub.2 represents a weight of the silica polymers in
terms of oxides.
If the coating solution for forming a transparent conductive coating
applied to the surface of the substrate contains excessively large amount
of the matrix component, the resulting coating decreases in conductivity
and, on the contrary, if the amount of the conductive particles contained
in said coating solution is excessively large, dispersibility in the
coating solution of the conductive particles or preservability of the
coating solution deteriorates, or the coating formed therefrom
deteriorates sometimes in transparency or in adhesion to the substrate.
In the coating solution for forming a transparent conductive coating, the
sum total of solids content of the conductive particles and matrix is
desirably not more than 15% by weight.
The organic solvents used as dispersion media for the above-mentioned
conductive particles and matrix include, though not particularly limited,
for example, alcohols such as methanol, ethanol, propanol, butanol,
diacetone alcohol, furfuryl alcohol, ethylene glycol and hexylene glycol;
esters such as methyl acetate and ethyl acetate; ethers such as diethyl
ether, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether,
ethylene glycol monobutyl ether, diethylene glycol monomethyl ether and
diethylene glycol monoethyl ether; and ketones such as acetone, methyl
ethyl ketone, acetylacetone and acetoacetic ester.
Such coating solution of the invention for forming a transparent conductive
coating as obtained in the manner mentioned above may also be incorporated
with various other components for the purpose of imparting additionally
another function to the coating solution.
For example, a display panel having a transparent conductive coating
prepared by using the coating solution incorporated with small amounts of
a dye, particularly a face plaze of CRT, will absorb light of specific
wavelengths to improve contrast.
Furthermore, a refractive index of the coating can be adjusted by allowing
a metallic oxide such as ZrO.sub.2, TiO.sub.2 or CeO.sub.2, or a compound
oxide thereof to coexist in said coating. In this case, the particulate
metallic oxide or its precursor is added to the coating solution.
The precursor useful in that case includes acetylacetonate chelate
compounds such as dibutoxybisacetylacetonate zirconium and
dibutoxybisacetylacetonate titanium, or metallic alkoxide compounds such
as tetrabutoxy zirconium and tetraisopropoxy titanium.
Further, it is also possible to add as an auxiliary binder a silicic acid
solution obtained by dealkalization of an alkali metal silicate.
II) Conductive Substrate
The conductive substrate of the present invention comprises a substrate
such as glass or plastics and a transparent conductive coating formed on
the surface of said substrate by coating said surface with the
above-mentioned coating solution for forming a transparent conductive
coating.
In this connection, the substrate having the above-mentioned transparent
conductive coating formed on their surface have a surface resistivity of
10.sup.3 -10.sup.10 .OMEGA./.quadrature.. Of the conductive substrate
mentioned above, those which are not subjected to non-glare treatment have
a haze of not more than 1% , and those which are subjected to non-glare
treatment have a glossiness of 40-90%.
The conductive substrates of the invention may have a transparent
protective coating formed on the surface of the transparent conductive
coating.
The transparent conductive coating formed on the surface of the conductive
substrate of the invention contains a minor proportion of conductive
particles having a large particle diameter. That is, this transparent
conductive coating is formed by using a coating solution wherein the
amount of particles having a particle diameter of not more than 600 .ANG.
is more than 60% by weight and the amount of particles having a particle
diameter of more than 1000 .ANG. is not more than 15% by weight. On that
account, the surface of this transparent conductive coating is excellent
in smoothness even when said coating is made thin, and almost free from
uneveness due to the presence of large particles in said coating. In the
conductive substrates of the invention, therefore, the formation of
scattered light on the surface of the transparent conductive coating can
be decreased and, at the same time, the formation of scattered light
caused by the particles in this coating can be inhibited.
As mentioned above, in the present invention the particle diameter range of
the conductive particles contained in the coating solution for forming a
transparent conductive coating is specifically defined above and, in
addition thereto, the content of particles having a particle diameter of
not more than 100 .ANG. is defined to be more than 5% by weight, hence the
proportion of large particles contained in the coating solution is far
smaller in comparison with the coating solutions which are not so defined.
Accordingly, in the coating formed on the substrate by using the coating
solution of the invention as mentioned above, practically no large
particle is present. On that account, the formation of scattered light
caused by the particles having a large particle diameter present in the
transparent conductive coating as formed is further decreased, and the
conductive substrates of the invention having formed the transparent
conductive coating on their surface thus obtained are found to be
excellent in transparency and low in haze.
In particular, there is obtained a display panel for a display device
having excellent resolving power by forming the above-mentioned
transparent conductive coating on said panel.
In the transparent conductive coating formed on the conductive substrate of
the invention, the conductive particles are uniformly dispersed, because
the coating solution used contains a minor proportion of large particles
and particles having particle diameters falling within the specific range
as defined above.
Accordingly, when the transparent conductive coating having the same
surface resistivity as in coatings obtained from conventional coating
solutions containing a major proportion of conductive particles having
large particle diameter is desired to obtain, said conductive coating can
be reduced in thickness.
Because the silica polymers having a specific distribution in degree of
polymerization as mentioned above are used as matrices in the coating
solution of the invention for forming a transparent conductive coating,
the coating solution as applied to the substrate will cure to form a
compact coating practically free from voids (pores or minute cracks).
Accordingly, the coating formed by means of the coating solution of the
invention comprising a combination of the matrix and fine conductive
particles having such characteristic features is extremely even and smooth
on its surface.
The term smoothness as used in the invention means that the coating is free
from unevenness and small in surface roughness and, in addition thereto,
said coating has a denseness free from the above-mentioned void.
The conductive substrates of the invention are excellent in optical
characteristics such as transparency and low haze, and of course excellent
in surface hardness. Also, they are excellent in durability against an
acid or alkali atmosphere or the circumstances of high temperature and
humidity and, at the same time, excellent in stain resistance. The term
stain resistance as used in the invention is intended to designate such
properties of the coating that the coating is difficult to stain and, even
when said coating stains, the substance that has stained said coating can
readily be removed therefrom.
The transparent conductive coating formed on the surface of the substrate
of the invention has a thickness desirably of about 500-7000 .ANG..
The conductive substrates of the invention may have a transparent
projective coating further formed on the transparent conductive coating
formed already on said substrate.
The conductive substrates having a surface resistivity falling within the
range of 10.sup.3 .OMEGA./.quadrature. to 10.sup.10 .OMEGA./.quadrature.,
and a haze of not more than 1% can be obtained by forming the transparent
conductive coating having the above-mentioned coating thickness on the
surface of said substrate and, if necessary, by forming further the
transparent protective coating on said transparent conductive coating.
Further, when the non-glare treatment as will be mentioned later is
carried out at the time of forming the coating on the substrate having the
same surface resistivity as obtained in the case where no non-glare
treatment is carried out, and a glossiness of 40-90%.
Furtheremore, by controlling optical characteristics of the above-mentioned
transparent conductive coating and transparent protective coating in the
manner as will be mentioned later, there can be obtained a conductive
substrate having a surface resistivity of 10.sup.3 -10.sup.10
.OMEGA./.quadrature., a glossiness of 40-90% and a surface reflectance of
not more than 1%.
III) Process for Preparing Conductive Substrate
The conductive substrates of the present invention may be prepared by
coating the surface of the substrate such as glass or plastics with the
coating solution for forming a transparent conductive coating by means of
a method such as dipping, spinner, spraying, roll coater or flexo
printing, followed by drying at ordinary temperature to 90.degree. C. and
then curing by application of heat of more than 100.degree. C.
Further, the conductive substrates which exhibit the above-mentioned
effects thereof more prominently can be obtained by the following
procedure.
That is, after the above-mentioned coating or drying process or during the
drying process, the transparent conductive coating coated and still at an
uncured stage is irradiated with an electromagnetic wave having a
wavelength shorter than that of visible light, or the transparent
conductive coating at an uncured stage is exposed to a gas atmosphere
wherein curing reaction of the conductive coating as coated is promoted.
The electromagnetic wave with which the uncured transparent conductive
coating is irradiated before heating includes concretely ultraviolet rays,
electron rays, X-rays and gamma rays, and of these rays, preferred are
ultraviolet rays. The uncured transparent conductive coating as coated is
irradiated with ultraviolet rays having an energy amount of more than 100
mJ/cm.sup.2, preferably more than 1000 mJ/cm.sup.2 by using as a source of
ultraviolet rays, for example, a mercury lamp wherein an intensity of
emission becomes maximal at about 250 nm and 360 nm, and an intensity of
light is more than 10 mW/cm.sup.2, preferably 100 mW/cm.sup.2.
The gas which promotes the curing reaction of the transparent conductive
coating at an uncured stage before heating includes, for example, ammonia
or ozone. The promotion of curing of the transparent conductive coating as
formed may be accomplished, for example, by treating said coating at an
uncured stage for 1-60 minutes with such active gas as mentioned above in
an active gas atmosphere having a gas concentration of 100-10,000 ppm,
preferably 1,000-10,000 ppm.
By carrying out the above-mentioned cure promotion treatment,
polymerization of the matrix is promoted and, at the same time,
evaporation of water and solvent remaining in the coating is also
promoted. As the result, heat-curing conditions such as a heating
temperature and heating time to be employed in the subsequent heating
process can be moderated.
In the invention, when the surface of the substrate such as glass or
plastics is coated by the spray method with the coating solution, while
preheating said surface to about 40.degree.-90.degree. C. and maintaining
said temperature, and the thus coated substrate is subjected to
heat-curing treatment, a number of minute ring-like irregularities are
formed on the surface of the coating, whereby a non-glare transparent
conductive substrate with little glare is obtained. Accordingly, when the
transparent conductive substrate is prepared by such procedure as
mentioned above, performance of the substrate such as stain resistance and
durability will not deteriorate, though an apparent surface roughness of
the surface of the coated film is lost more or less.
Furthermore, prior to this heat-curing treatment, the above-mentioned cure
promotion treatment may also be carried out.
As mentioned previously, the transparent protective coating may be formed
on the transparent conductive coating formed on the substrate by means of
the above-mentioned procedure.
The transparent protective coating mentioned above desirably has a
thickness of not more than about 0.5 .mu.m, and this transparent
protective coating may be formed by the same method as used in forming the
transparent conductive coating on the substrate, including the steps of
coating, drying and heating in succession. In that case, the
above-mentioned cure promotion treatment and/or non-glare treatment may be
carried out at the time of forming the transparent protective coating.
The coating solutions for forming a transparent protective coating
preferably used in the above case include the above-mentioned coating
solutions for forming a transparent conductive coating from which the
conductive particles have been omitted, or the coating solutions
containing the conductive particles in amounts smaller than that of the
conductive particles contained in the above-mentioned coating solution for
a transparent conductive coating.
In preparing the conductive substrate by laminating the conductive coating
and the transparent protective coating successively on the substrate,
coating solutions incorporated with refractive index adjusting compound
particles, that is, compound particles capable of adjusting refractive
index of each coating, are used in amounts controlled so that a coating
having desired refractive index and film thickness is formed from each
coating solution on the substrate, whereby the conductive substrate having
a reflection preventive ability wherein the reflectance of external light
is not more than 1%.
In that case, the compound particles to be added to the coating solution
for forming a transparent conductive coating are metallic oxide particles
such as ZrO.sub.2, TiO.sub.2 or CeO.sub.2, compound oxide particles
thereof, or particles consisting of precursor thereof.
The compound particles to be added to the coating solution for forming a
transparent protective coating are particles of MgF.sub.2 or CaF.sub.2.
IV) Display Device Provided with Transparent Conductive Substrate
The display devices of the present invention are those which display images
electrically such as Braun tube (CRT), fluorescent indicator pipe (FIP),
plasma display (PDP), liquid crystal display (LCD), etc., and a
transparent conductive coating is formed on the face-plate of the display
panel thereof. That is, the display devices of the present invention are
equipped with a display panel with a transparent conductive coating as a
transparent conductive substrate.
The transparent conductive coating is formed by using the above-mentioned
coating solution of the invention for forming a transparent conductive
coating.
The display panel with the transparent conductive coating thus formed is
excellent in conductivity, smoothness, durability, adhesion between the
coating and the substrate, and stain resistance. Furthermore, resolving
power of the displayed images observed through the display panel with the
transparent conductive coating is maintained at a high level.
In this connection, the display panels with the transparent conducive
coating have all a surface resistivity of 10.sup.3 -10.sup.10
.OMEGA./.quadrature.. The display panels comprising the transparent
conductive substrate not subjected to non-glare treatment have a haze of
not more than 1% and a resolving power of more than 70 bar/cm, and the
display panel comprising the transparent conductive substrate subjected to
non-glare treatment have a glossiness of 40-90% and a resolving power of
more than 60 bar/cm. The term resolving power as used herein is intended
to designate a value measured by the following method.
As shown in FIG. 1, a bar chart 1 having printed a given number per 1 cm of
bars 2 is applied to one side of a test display panel on which no film is
formed, and said panel is placed in a test device 4 shown in FIG. 2 so
that the side of said panel to which the bar chart has been applied is
positioned inside the test device 4. In the test device 4 having a white
inner wall 2 pieces of fluorescent lamps (20 W) are placed laterally at an
interval of 30 cm at a distance of 50 cm from the position of the test
display panel. In this case, the bar chart used is changed successively
from one having a small number of bars per 1 cm to the other having a
larger number of bars per 1 cm, and the maximal number of bars per 1 cm in
the bar chart that can be confirmed by visual observation is taken as a
resolving power.
In the display devices of the invention, the reflectance of the display
panel can be reduced to not more than 1% by forming on the face-plate of
the display panel a transparent conductive coating containing the
above-mentioned refractive index adjusting compound particles such as
TiO.sub.2 or ZrO.sub.2 and further forming a protective coating containing
the above-mentioned refractive index adjusting compound particles such as
MgF.sub.2 or CaF.sub.2 on the surface of the transparent conductive
coating. That is, reflection of light occurring on surface of the display
picture can be prevented, whereby the picture displayed on the display
panel becomes easy to see.
In the display devices of the present invention, various improvements such
as prevention of reflection of light on the displayed picture can be made,
for example, by forming a special protective coating on a transparent
conductive coating formed on the face-plate of the display panel.
Effect of the Invention
The coating solutions of the present invention for forming a transparent
conductive coating which contain conductive particles having a specific
particle size distribution and a matrix comprising of a specific silica
polymer are capable of forming on the surface of a substrate conductive
coatings excellent in adhesivity and surface smoothness as well as in
durabiling such as water resistance and alkali resistance, and also
excellent in optical characteristics such as transparency, haze and
glossiness.
That is, the conductive particles are fine particles having specific
particle size distribution with a minor proportion of large particles,
hence transparent conductive coatings which are smooth and low in haze
even when the coating thickness of said coating is made thin.
The conductive particles are well dispersed in the coating solution, and
therefore, the coatings sufficiently low in surface resistivity can be
obtained even when the amount of the conductive particles is reduced.
Because the matrix comprises a silica polymer having a specific degree of
polymerization, when the above-mentioned conductive particles are
dispersed in the coating solution containing said matrix, the resulting
coating solution is practically free from aggregation of the conductive
particles, and in the coating formed therefrom the monodispersed state of
the conductive particles is maintained. Accordingly, extremely f | | |