The present invention relates to an optically transparent conductive material mainly used for touchscreens. The present invention particularly relates to an optically transparent conductive material suitably used for optically transparent electrodes of projected capacitive touchscreens.
Touchscreens are widely used as input means on displays of electronic devices such smartphones, personal digital assistants (PDAs), laptop computers, office automation equipment, medical equipment, and car navigation systems.
There are various touchscreens that utilize different position detection methods, such as optical, ultrasonic, surface capacitive, projected capacitive, and resistive touchscreens. In the case of resistive touchscreens, an optically transparent electrode as a touch sensor includes an optically transparent conductive material and a glass plate with an optically transparent conductive layer, which opposite each other across a spacer. In such a structure, an electrical current is applied to the optically transparent conductive material, and the voltage on the glass plate with an optically transparent conductive layer is measured. In the case of capacitive touchscreens, an optically transparent electrode as a touch sensor essentially includes an optically transparent conductive material including a support and an optically transparent conductive layer on the support. Owing to such a structure with no movable parts, the capacitive touchscreens have high durability and high optical transparency, and are thus used in various applications. In addition, projected capacitive touchscreens enables simultaneous multipoint detection, and are thus widely used in devices such as smartphones and tablet PCs.
Conventional optically transparent conductive materials used for optically transparent electrodes of touchscreens include an optically transparent conductive layer made of an indium-tin oxide (ITO) conductive film on a support. Yet, due to high refractive index and high surface reflectivity, ITO conductive films may reduce the optical transparency of optically transparent conductive materials. Additionally, due to low flexibility, ITO conductive films may crack when optically transparent conductive materials are bent, causing an increase in electrical resistance of the optically transparent conductive materials.
An optically transparent conductive material known as an alternative to ones that include optically transparent conductive layers made of ITO conductive films includes an optically transparent support and a pattern of thin metal wires as an optically transparent conductive layer on the support, in which, for example, a net-like pattern of thin metal wires is formed by adjusting the wire width and pitch of the pattern of thin metal wires and also by adjusting the shape of the pattern. This technique provides an optically transparent conductive material capable of maintaining a high optical transparency and having a high conductivity. With regard to the net-like pattern of thin metal wires (hereinafter also referred to as a “metal pattern”), it is known that a repetitive unit of any shape can be used. For example, Patent Literature 1 discloses repetitive units including triangles such as equilateral triangles, isosceles triangles, and right triangles; quadrangles such as squares, rectangles, rhombuses, parallelograms, and trapezoids; (regular) n-sided polygons such as (regular) hexagons, (regular) octagons, (regular) dodecagons, and (regular) icosagons; circles; ellipses; stars; and combinational patterns of two or more thereof.
A semi-additive method is known as a method of producing an optically transparent conductive material having the net-like metal pattern. In this method, a thin catalytic layer is formed on an optically transparent support, a resist pattern is formed thereon, a metal layer is stacked on a resist opening portion by plating, and lastly, a resist layer and a base metal protected by the resist layer are removed, whereby a metal pattern is formed.
Recently known techniques include a method in which a silver halide photosensitive material for a silver salt diffusion transfer process is used as a conductive material precursor. In this method, a silver halide photosensitive material (conductive material precursor) including at least a physical development nuclei layer and a silver halide emulsion layer in the stated order on an optically transparent support is acted on by a soluble silver salt-forming agent and a reducing agent in an alkaline solution, whereby a metal (silver) pattern is formed. This patterning method enables reproduction of patterns having a uniform wire width, and can also provide high conductivity with a narrower wire width compared to patterns produced by other methods, because silver has the highest conductivity of all metals. Further, a layer having a metal pattern produced by this method is advantageous in that it has higher flexibility and higher bending resistance than ITO conductive films.
Yet, since an optically transparent conductive material having such a metal pattern on an optically transparent support is superimposed on a display, the period of the metal pattern and the period of a display element interfere with each other, causing a problem of moire. Recent use of displays having various resolutions further complicates the problem.
To solve this problem, for example, Patent Literature 2 and the like propose methods of suppressing interference by using a traditional random pattern as a metal pattern. For example, such a traditional random pattern is described in “Mathematical Models of Territories—Introduction to Mathematical Engineering through Voronoi diagram” (Non-Patent Literature 1).
As disclosed in Patent Literature 3, a known example of a projected capacitive touch sensor is an optically transparent conductive material including two optically transparent conductive layers that include multiple linear electrodes connected to terminal areas via a peripheral wiring part, wherein the two optically transparent conductive layers are bonded together in such a manner that the linear electrodes of the respective optically transparent conductive layers are substantially orthogonal to each other via an insulation layer. Commonly used linear electrodes have a shape called “diamond pattern” in which intersections between linear electrodes of respective optically transparent conductive layers are contracted.
Linear electrodes made of the net-like pattern of thin metal wires have lower electrostatic discharge (ESD) resistance than ITO. It is because the thin metal wires have a lower electrical resistance than ITO, and a large amount of current can thus easily flow therethrough. The pattern of thin metal wires is formed from thin metal wires in the net-like form. The amount (area) of thin metal wires is smaller particularly in contracted portions of the diamond pattern than in other portions, and the current flowing through the thin wires is thus concentrated in the in contracted portions. This easily causes overcurrent.
Further, in the random metal pattern described above, a portion where the distribution of thin metal wires is scarce and a portion where the distribution is dense appear at random, so that the amount of thin metal wires per unit area is uneven. Disconnection due to ESD (electrostatic breakdown) easily occurs particularly when the amount of thin metal wires is small at the contracted portions of the diamond pattern where the current is concentrated.
Static electricity is known to be a problem particularly when an optically transparent conductive material is processed and produced in the form of a roll of a long sheet. Usually, countermeasures are taken on-site by using a static eliminator or maintaining the humidity at a certain level or higher. The optically transparent support which is an insulator is easily electrically charged. Friction and separation occur when the optically transparent support is unrolled or rolled up, causing static electricity. When the potential difference is high, electric discharge easily occurs in sensor parts which are conductive. In addition, a protective film is usually attached to protect a surface of the optically transparent conductive material. The protective film used for such an application is easily electrically charged. When the potential difference increases due to removal of the protective film, electric discharge easily occurs in the sensor parts. Thus, when such electric discharge occurs, disconnection (electrostatic breakdown) occurs at a portion susceptible to overcurrent in the sensor parts, which causes a significant decrease in the touchscreen yield.
In order to prevent electrostatic breakdown, Patent Literature 4 discloses an optically transparent conductive material provided with ground wires whose minimum inter-wire distance is smaller than the minimum inter-wire distance of peripheral wires. Patent Literature 5 discloses an optically transparent conductive material including a protective wire having electrical characteristics in which the electrical resistance decreases as the voltage increases. Yet, these materials are to prevent a momentary flow of current into the peripheral wiring part, and a technique that relates to the ESD resistance of the sensor parts is yet to be disclosed.
Patent Literature 1: JP 2013-30378 A
Patent Literature 2: JP 2011-216377 A
Patent Literature 3: JP 2006-511879 T
Patent Literature 4: JP 2016-15123 A
Patent Literature 5: JP 2016-162003 A
Non-Patent Literature 1: Mathematical Models of Territories—Introduction to Mathematical Engineering through Voronoi diagram (published by Kyoritsu Shuppan Co., Ltd., February 2009)
The present invention aims to provide an optically transparent conductive material that provides excellent visibility without causing moire even when superimposed on a display, in which sensor parts have excellent ESD resistance.
The above problem is essentially solved by an optically transparent conductive material including: an optically transparent support; and an optically transparent conductive layer on the optically transparent support, the optically transparent conductive layer being electrically connected to a terminal area and including sensor parts extending in one direction, wherein the sensor parts are each made of an irregular net-like pattern of thin metal wires, each sensor part has varying widths and includes corridor portions where the width of the sensor part is relatively narrow and other portions where the width of the sensor part is relatively wide, and the following relation is satisfied: 1.05X≤A≤1.20X, where A is an average number of intersections in the pattern of thin metal wires per unit area in the corridor portions, and X is an average number of intersections in the pattern of thin metal wires per unit area in other portions.
Preferably, the sensor parts extending in one direction each have a shape in which the corridor portions appear periodically. Preferably, the corridor portions each have a width of 1 to 2 mm and a length of 1.5 to 3 mm in the direction in which the sensor parts extend. Preferably, when the unit area is the area of one corridor portion, the average number A of intersections is 10 or more. Preferably, the irregular net-like shape is a Voronoi diagram and/or a shape obtained by deforming a Voronoi diagram.
The present invention can provide an optically transparent conductive material that provides excellent visibility without causing moire even when superimposed on a display, in which the sensor parts have excellent ESD resistance.
Hereinafter, the present invention is described in detail with reference to the drawings, but it is needless to say that the present invention is not limited to the following embodiments, and various alterations and modifications may be made without departing from the technical scope of the invention.
A projected capacitive touchscreen has a structure in which an upper electrode layer including multiple linear electrodes and a lower electrode layer including multiple linear electrodes are stacked together with an insulation layer therebetween. Using an optically transparent support as an insulation layer, an upper electrode layer which is an optically transparent conductive layer may be disposed on one surface of the optically transparent support, and a lower electrode layer which is an optically transparent conductive layer may be disclosed on the other surface. Alternatively, the upper electrode layer and the lower electrode layer may be disposed on separate optically transparent supports, and an optically transparent support side of the upper electrode layer may be bonded to an electrode layer side of the lower electrode layer with an optical clear adhesive (OCA).
The sensor parts 21 in
The upper electrode layer 1 shown in
The sensor parts 21 can be formed in a pattern with a period in the first direction (x-direction in the figure).
The lower electrode layer 2 shown in
In the optically transparent conductive material of the present invention, each sensor part has varying widths and includes corridor portions where the width of the sensor part is relatively narrow and other portions where the width of the sensor part is relatively wide.
The virtual outlines of the sensor parts are indicated by boundary lines of regions defined by connecting the disconnection parts of the thin metal wires separating the sensor parts from the dummy parts. When the virtual outlines of the sensor parts are linear and parallel to each other in the corridor portions, only a portion where the sensor part is the narrowest is a corridor portion. When the virtual outlines of the sensor parts are not linear or parallel to each other, a portion whose width is not more than 1.1 times the narrowest width of the sensor part is a corridor portion.
The size of the corridor portions can be set to any size according to the performance of the touch sensor. Yet, when W is too small, it increases the electrical resistance of the sensor parts. When W is too wide, it results in an increased area where the corridor portions overlap the sensor parts in the lower electrode. Disadvantageously, both cases cause a decrease in the performance of the touch sensor. L2 can be suitably determined according to the size of the width W of the corridor portions in the lower electrode layer. The width W of each corridor portion is preferably in the range of 1 to 2 mm, and the length L2 of each corridor portion is preferably in the range of 1.5 to 3 mm.
In the present invention, when the length (L2 in
A frame 61 shows a region corresponding to a corridor portion, and the number of intersections in the corridor portion is also 49, as in the corridor portion shown in
An optically transparent conductive material which is obtained by repeatedly arranging the metal patterns shown in
The above description described the method of determining A and X, which can be expediently used for the diamond pattern that is a preferred shape of the sensor part in the present invention. When the shape of the sensor part is different from the diamond pattern or is not a repeated pattern with a period in the first direction, A can be determined by counting the total number of intersections included in all the corridor portions defining the sensor parts and by multiplying the total number by the ratio of the unit area to the total area of the corridor portions. X can be determined by counting the total number of intersections included in all the other portions defining the sensor portions (i.e., all the portions other than the corridor portions) and by multiplying the total number by the ratio of the unit area to the total area of the other portions.
Next, irregular net-like patterns of thin metal wires forming the sensor parts and the dummy parts in the present invention are described. Examples of the irregular pattern include those obtained with irregular geometric shapes typified by, for example, a Voronoi diagram, a Delaunay diagram, and a Penrose tiling pattern. In the present invention, a net-like pattern formed with Voronoi edges based on generators (hereinafter referred to as a “Voronoi diagram”) is preferably used. With the use of a Voronoi diagram, it is possible to obtain an optically transparent conductive material that can be used to provide a touchscreen with excellent visibility. Voronoi diagrams are known diagrams that have been applied in various fields including the field of information processing.
A method for arranging generators is described with reference to
In the present invention, in order to prevent “grains”, it is preferred to tile the plane with the original polygons 83 of the same shape and the same size as shown in
Preferred shapes of the original polygon are quadrangles (such as squares, rectangles, and rhombuses), triangles, and hexagons. In order to prevent the phenomenon of grains, more preferred are quadrangles, and particularly preferred are rectangles each having a longer side to shorter side ratio of 1:0.7 to 1:1. The length of one side of the original polygon is preferably 100 to 2000 μm, more preferably 120 to 800 μm. In the present invention, the Voronoi edge is most preferably a straight line, but a different line such as a curved line, a wavy line, or a zigzag line may also be used. The wire width of each metal pattern of the sensor parts 21 and the dummy parts 22 is preferably 1 to 20 μm, more preferably 2 to 7 μm, in order to achieve conductivity and optically transparent in a balanced manner.
The irregular net-like shape in the present invention is also preferably a shape obtained by enlarging or reducing the Voronoi diagram obtained by the above method in any direction.
As shown in
As described above for
In the present invention, the sensor parts 21 and the dummy parts 22 are each formed in a net-like metal pattern. Preferred examples of the metal include gold, silver, copper, nickel, aluminium, and composite materials thereof. Peripheral wiring parts 23 and terminal areas 24 are also preferably formed in metal patterns made of the same metal composition as that of the sensor parts 21 and the dummy parts 22 in view of production efficiency. Examples of the method for forming these metal patterns include known methods such as a method in which a silver halide photography photosensitive material is used; a method in which a silver image (pattern of thin silver wires) obtained using a silver halide photography photosensitive material by the above method is electroless plated or electroplated; a method in which conductive ink such as silver ink or copper ink is printed by a screen printing method; a method in which conductive ink such as silver ink or copper ink is printed by an ink-jet method; a method in which a conductive layer is formed by vapor deposition or sputtering, and a resist film is formed thereon, followed by exposure, development, and etching in a sequential manner, and then resist layer removal; and a method in which metal foil such as copper foil is attached, and a resist film is formed thereon, followed by exposure, development, and etching in a sequential manner, and then resist layer removal. Particularly preferred is a silver salt diffusion transfer process because a metal pattern to be produced can be made thin and a very fine metal pattern can be easily formed with this process.
With regard to the thickness of the metal pattern produced by the above techniques, a pattern that is too thick may be difficult to post-process (e.g., bonding to other members), and a pattern that is too thin may fail to provide necessary conductivity to a touchscreen. Thus, the thickness is preferably 0.01 to 5 μm, more preferably 0.05 to 1 μm.
In the optically transparent conductive material of the present invention, the total light transmittance of the sensor parts 21 and the total light transmittance of the. dummy parts 22 are preferably 80% or more, more preferably 85% or more, particularly preferably 88.5% or more. In addition, the difference between the total light transmittance of the sensor parts 21 and the total light transmittance of the dummy parts 22 is preferably within 0.5%, more preferably within 0.1%, particularly preferably 0%. The haze value of the sensor parts 21 and the dummy part 22 is preferably 2 or less. Further, the b* value indicating the hue of the sensor parts 11 and the dummy parts 12 is preferably 2 or less, more preferably 1 or less.
The optically transparent support of the optically transparent conductive material of the present invention is preferably a known optically transparent support such as glass, polyester resins such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN), acrylic resin, epoxy resin, fluororesin, silicone resin, polycarbonate resin, diacetate resin, triacetate resin, polyarylate resin, polyvinyl chloride, polysulfone resin, polyether sulfone resin, polyimide resin, polyamide resin, polyolefin resin, or cyclic polyolefin resin. The term “optical transparency” as used herein means that the total light transmittance is 60% or higher. The total light transmittance of the optically transparent support is preferably 80% or higher. The thickness of the optically transparent support is preferably 50 μm to 5 mm. The optically transparent support may also include a known layer, such as an anti-fingerprint layer, a hard coat layer, an antireflection layer, and an antiglare layer.
In the present invention, an OCA may be used to bond the optically transparent support side of the upper electrode layer 1 to the electrode layer side of the lower electrode layer 2 as shown in
The present invention is described in details with reference to examples below, but the present invention is not limited to the following examples as long as modifications are within the scope of the present invention.
The optically transparent support was a 100-μm-thick polyethylene terephthalate film having a total light transmittance of 92%.
Next, in accordance with the following formulation, a physical development nuclei layer coating liquid was prepared, applied to the optically transparent support, and dried to form a physical development nuclei layer.
Liquid A and Liquid B were mixed with stirring for 30 minutes, and then passed through a column filled with an ion exchange resin, whereby a palladium sulfide sol was obtained.
Subsequently, an intermediate layer, a silver halide emulsion layer, and a protective layer having compositions shown below were applied to the physical development nuclei layer in the stated order from the closest to the optically transparent support, followed by drying, whereby a silver halide photosensitive material was obtained. The silver halide emulsion was produced by a common double jet mixing method for photographic silver halide emulsions. The silver halide emulsion was prepared from 95% by mole of silver chloride and 5% by mole of silver bromide to have an average particle diameter of 0.15 μm. The silver halide emulsion obtained as above was subjected to gold and sulfur sensitization using sodium thiosulfate and chloroauric acid by the usual method. The silver halide emulsion obtained as above contained 0.5 g of gelatin per gram of silver.
The silver halide photosensitive material obtained as above was brought into tight contact with a transparent manuscript having the pattern image shown in
In a transparent manuscript having the pattern image shown in
Subsequently, the silver halide photosensitive material was immersed in the diffusion transfer developer shown below at 20° C. for 60 seconds. Then, the silver halide emulsion layer, the intermediate layer, and the protective layer were washed off with warm water at 40° C. and dried, whereby an optically transparent conductive material 1 having a pattern of thin metal wires (hereinafter also referred to as a “metal silver image”) as an upper electrode layer was obtained. All the metal silver images on the optically transparent conductive layers of the optically transparent conductive material obtained above and other optically transparent conductive materials shown below each had the same shape and the same wire width as in the image pattern of the transparent manuscript used. The area of the corridor portion was used as the unit area. The average number A of intersections in the corridor portion was 49, and the average number X of intersections in the unit area at the center of the diamond portion was 51.
The total volume was made up to 1000 ml with water. The pH was adjusted to 12.2.
An optically transparent conductive material 2 was obtained as in the optically transparent conductive material 1, except that in a transparent manuscript having the pattern image shown in
An optically transparent conductive material 3 was obtained as in the optically transparent conductive material 2, except that in a transparent manuscript having the pattern image shown in
An optically transparent conductive material 4 was obtained as in the optically transparent conductive material 2, except that in a transparent manuscript having the pattern image shown in
An optically transparent conductive material 5 was obtained as in the optically transparent conductive material 2, except that in a transparent manuscript having the pattern image shown in
An optically transparent conductive material 6 including a metal silver image as the lower electrode layer was produced as in the optically transparent conductive material 1, except a different transparent manuscript was used which was produced by changing the pattern of the transparent manuscript from the one shown in
An optically transparent conductive material 7 including a metal silver image as the lower electrode layer was produced as in the optically transparent conductive material 2, except a different transparent manuscript was used which was produced by changing the pattern of the transparent manuscript from the one shown in
An optically transparent conductive material 8 including a metal silver image as the lower electrode layer was obtained as in the optically transparent conductive material 7, except that the transparent manuscript was changed to one including the Voronoi diagram used in the optically transparent conductive material 3. The average number A of intersections in the corridor portion was 60, and the average number X of intersections in the unit area at the center of the diamond portion was 51.
An optically transparent conductive material 9 including a metal silver image as the lower electrode layer was obtained as in the optically transparent conductive material 7, except that the transparent manuscript was changed to one including the Voronoi diagram used in the optically transparent conductive material 4. The average number A of intersections in the corridor portion was 62, and the average number X of intersections in the unit area at the center of the diamond portion was 51.
An optically transparent conductive material 10 including a metal silver image as the lower electrode layer was obtained as in the optically transparent conductive material 7, except that the transparent manuscript was changed to one including the Voronoi diagram used in the optically transparent conductive material 5. The average number A of intersections in the corridor portion was 64, and the average number X of intersections in the unit area at the center of the diamond portion was 51.
The optically transparent conductive materials 1 to 10 were tested to evaluate the ESD resistance according to the following procedure. First, the electrical resistance across the ends of each of 10 sensor parts of each optically transparent conductive material was measured using a tester. Then, the optically transparent conductive material was superimposed on a copper plate in such a manner that there was no contact between the surface with the metal silver image and the copper plate. Further, a 100-μm thick polyethylene terephthalate film was placed on the surface with the metal silver image, and seasoning was performed at 23° C. and 50% for one day. Subsequently, an electrostatic breakdown tester (DITO ESD Simulator available from EM TEST, hereinafter referred to as “DITO”) was used to perform an electrostatic breakdown test. For the electrostatic breakdown test, a DM1 was used as a discharge tips. Then, a ground wire of DITO was attached to the copper plate, and the tip of DITO was brought into contact with the 100-μm thick PET film, at a central portion in the direction in which each sensor part extended. Electrostatic discharge was performed one time for each sensor at a voltage of 8 kV. After the discharge, the PET film was removed, and the electrical resistance across the ends of each of the 10 sensor parts was measured to evaluate the ESD resistance by comparing the electrical resistance before and after the electrostatic breakdown test. Specifically, an optically transparent conductive material in which all the 10 sensor parts showed an increase in electrical resistance by less than 5% was rated as good; an optically transparent conductive material in which one sensor part showed an increase in electrical resistance by 5% or more was rated as fair; and an optically transparent conductive material in which two or more sensor parts showed an increase in electrical resistance by 5% or more was rated as poor. Table 1 shows the results, including the average numbers A and X of intersections and their ratios (A/X). All the optically transparent conductive materials of the present invention were rated as good in the ESD resistance evaluation.
The optically transparent conductive materials 1 to 10 obtained and 2-mm thick chemically strengthened glass plates were bonded together using an OCA (MHN-FWD 100 available from Nichiei Kako Co., Ltd.) to produce touchscreens 1 to 17. Specifically, each touchscreen was produced by bonding a glass plate, an OCA, one of the optically transparent conductive materials 1 to 5, an OCA, and one of the optically transparent conductive materials 6 to 10, in the stated order, in such a manner that the surface with the metal silver image of each optically transparent conductive material was oriented toward the glass plate and that these layers were aligned with each other using alignment marks (+) on the four corners.
The produced touchscreens were individually placed on a screen of a 21.5 wide liquid crystal monitor (I2267FWH available from AOC) displaying a solid white image. A touchscreen in which moire or unevenness was clearly visible was rated as poor; a touchscreen in which moire or unevenness was visible at a closer look was rated as fair; and a touchscreen in which moire or unevenness was completely invisible was rated as good. Table 2 shows the results, including the combinations of the optically transparent conductive materials. All the combinations of the optically transparent conductive materials of the present invention were rated good. It was found that use of an optically transparent conductive material having A/X of more than 1.20 reduced the visibility.
The results in Table 1 and Table 2 show that the present invention can provide optically transparent conductive materials that provide excellent visibility without causing moire even when superimposed on a display, in which sensor parts have excellent ESD resistance.
1: upper electrode layer (optically transparent conductive layer)
2: lower electrode layer (optically transparent conductive layer)
3, 4: optically transparent support
5, 6: optically transparent conductive material
21, 31: sensor part
22, 32: a dummy part
23, 33: peripheral wiring part
24, 34: terminal area
41: corridor portion
51, 61, 62, 71, 72: frame
a, b: virtual outline
Number | Date | Country | Kind |
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2017-182972 | Sep 2017 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2018/033456 | 9/10/2018 | WO | 00 |