Patent Application
20090190073
The present invention relates to a phthalocyanine-series pigment fine particles used for color filters or the like and to a method of producing the pigment fine particles. The present invention particularly relates to a method of producing phthalocyanine-series pigment fine particles, phthalocyanine-series pigment fine particles, a pigment dispersion photoresist, and a colored transfer material, and a color filter and a liquid crystal display device which are obtained by using these materials and have a bright color tone, high coloring power, high contrast, and high weather resistance.
Pigments have been used in a variety of fields because each of them has a bright color tone, and high in coloring power and weather resistance. Among these pigments, many of practically important pigments have a fine particle form in general, and a bright tone, high coloring power and high contrast are obtained by preventing the pigments from being coagulated and by making these pigments into fine particles. However, in many cases, when the pigment particles are reduced in size by a physical method such as salt milling, the dispersion of the pigment particles results in a high viscosity liquid. Consequently, when the pigment dispersion liquid is prepared on an industrial scale, there arise the following problems: the pigment-dispersion liquid prepared can not be taken out of a dispersion machine, the dispersion liquid can not be transported through a pipeline, and further the dispersion liquid is solidified into a gel form during its storage so that the liquid can not be handled any more. Also, these pigments have the quality problem of deterioration in weather resistance.
Therefore, conventionally, to obtain a pigment-dispersion liquid or colored photosensitive composition improved in fluidity and dispersibility, it has been attempted to modify the surface of an organic pigment (see, for example, Patent Document 1 and Patent Document 2) and to use various dispersing agents (see, for example, Patent Document 3 and Patent Document 4). Further, reprecipitation of nanoparticles is disclosed in which a sample dissolved in a good solvent is injected into a poor solvent under stirring condition at a controlled temperature (see, for example, Patent Document 5).
When the colored photosensitive composition is used to form a colored image, its general procedure involves: applying a liquid of the colored photosensitive composition onto a substrate to form a layer formed by the colored photosensitive composition; and subjecting the layer to exposure and development. In this procedure, since an alkali aqueous solution has less environmental influence, it is often used as a developer to be used at the time of the development treatment. Hence, the colored photosensitive composition is required to allow to use the alkali developing solution for the development. In addition to it, a solvent (dispersion medium for a pigment) for use in the application liquid of the colored photosensitive composition is required to be easily dried after the application.
Further, it is generally required that a layer formed by the colored photosensitive composition is extremely thin and that the layer shows a high coloring density even in such small thickness. Accordingly, e.g., an organic pigment is to be dispersed in an organic solvent at a high concentration and uniformly reduced in size.
However, at present, there is no pigment-dispersion satisfying those requirements for the pigment with excellent dispersibility, fluidity, and the like; and pigment-dispersion photoresist containing the pigment-dispersion.
Patent Document 1: JP-A-11-269401 ((“JP-A” means unexamined published Japanese patent application)
Patent Document 2: JP-A-11-302553
Patent Document 3: JP-A-8-48890
Patent Document 4: JP-A-2000-239554
Patent Document 5: JP-A-2004-123853
Then, among pigments, phthalocyanine-series pigments are chemically stable owing to their structures and are superior in heat resistance and light fastness. Moreover, these phthalocyanine-series pigments have high coloring power and are therefore used as basic pigments for the B pixels and G pixels of color filters. It was expected that, by making these pigments into fine particles, improvement in contrast and further improvement in display characteristics would be achieved. However, only unsatisfactory results were obtained by the current beads dispersion method or salt milling method.
It is an object of the present invention to provide a color filter having a high contrast and weather resistance, a colored transfer material used for the color filter and a pigment dispersion photoresist; further to provide phthalocyanine-series pigment fine particles which are used for the above color filter, colored transfer material, pigment dispersion photoresist and the like having aforementioned excellent characteristics and which are superior in dispersibility and fluidity; and also to provide an excellent liquid crystal display device using these materials.
The above-described objects were achieved by the following means.
<1> A method of producing phthalocyanine-series pigment fine particles, the method comprising: dissolving a phthalocyanine-series pigment in a good solvent added with a pigment-dispersing agent comprising a compound represented by the following formula (I) or (II), to prepare a pigment solution; and mixing the pigment solution with a solvent which is compatible with the good solvent but is a poor solvent for the phthalocyanine-series pigment, to form fine particles of the phthalocyanine-series pigment having a size in the order of nanometer:
wherein Q represents a residue of an organic dye selected from anthraquinone-series dyes, azo-series dyes, phthalocyanine-series dyes, quinacridone-series dyes, dioxazine-series dyes, anthrapyrimidine-series dyes, anthanthrone-series dyes, indanthrone-series dyes, flavanthrone-series dyes, pyranthrone-series dyes, perynone-series dyes, perylene-series dyes, and thioindigo-series dyes; X represents —CO—, —CONH—Y2—, —SO2NH—Y2—, or —CH2NHCOCH2NH—Y2— (Y2 represents an alkylene group or an arylene group, each of which may be substituted); Y1 represents —NH— or —O—; Z represents a hydroxyl group or a group represented by formula (Ia) with the proviso that in the case where n is 1, Z may be —NH—X-Q; R1 and R2 each independently represent a substituted or unsubstituted alkyl group, alternatively, R1 and R2 represent groups that bond together to form a heterocyclic group which at least contains a nitrogen atom; m represents an integer of 1 to 6; and n represents an integer of 1 to 4;
wherein Y3 represents —NH— or —O—; and m, R1, and R2 have the same meanings as those in formula (I);
[Chemical formula 3]
A-N═N—X1—Y4 Formula (II)
wherein A represents a component capable of forming an azo dye together with X1—Y4; X1 represents a single bond, or a group selected from divalent connecting groups represented by structural formulae of formulae (i) to (v) set forth below; and Y4 represents a group represented by the following formula (III); and
wherein Z1 represents a lower alkylene group having 1 to 5 carbon atoms; —NR3 represents a lower alkylamino group having 1 to 4 carbon atoms, or a nitrogen-containing, 5- or 6-membered, saturated heterocyclic group; and a represents 1 or 2.
<2> A method of producing phthalocyanine-series pigment fine particles, the method comprising: dissolving a phthalocyanine-series pigment in a good solvent added with a pigment-dispersing agent comprising a compound represented by the following formula (IV), to prepare a pigment solution; and mixing the pigment solution with a solvent which is compatible with the good solvent but is a poor solvent for the phthalocyanine-series pigment, to form fine particles of the phthalocyanine-series pigment having a size in the order of nanometer:
wherein Me represents a methyl group.
<3> The method of producing phthalocyanine-series pigment fine particles according to the above item <1> or <2>, wherein the above good solvent is an amide-series solvent or a sulfoxide-series solvent and the above poor solvent is water or an alcohol-series solvent.
<4> The method of producing phthalocyanine-series pigment fine particles according to any one of the above items <1> to <3>, wherein the above phthalocyanine-series pigment is Pigment Blue 15:6, Pigment Green 7, or Pigment Green 36.
<5> Phthalocyanine-series pigment fine particles having a size in the order of nanometer and produced by any one of the production methods according to any one of the above items <1> to <3>.
<6> The phthalocyanine-series pigment fine particles according to the above item <5>, wherein the phthalocyanine-series pigment fine particles at least contain fine particles of Pigment Blue 15:6, Pigment Green 7, or Pigment Green 36.
<7> A pigment dispersion photoresist containing the phthalocyanine-series pigment fine particles according to the above item <5> or <6>.
<8> A colored transfer material, which has a pigment dispersion photoresist according to the above item <7> provided on a temporary support.
<9> A color filter prepared by using the pigment dispersion photoresist according to the above item <7>, or the colored transfer material according to the above item <8>.
<10> A liquid crystal display device installed with the color filter as described in the above item <9>;
<11> A method of producing phthalocyanine-series pigment fine particles, the method comprising: dissolving a phthalocyanine-series pigment in a good solvent, to prepare a pigment solution; mixing the pigment solution with a solvent which is compatible with the good solvent but is a poor solvent for the phthalocyanine-series pigment, to form fine particles of the phthalocyanine-series pigment in the order of nanometer; and adding a pigment-dispersing agent comprising a compound represented by the following formula (I) or (II) to the mixed solution in which the organic particles have been formed:
wherein Q represents a residue of an organic dye selected from anthraquinone-series dyes, azo-series dyes, phthalocyanine-series dyes, quinacridone-series dyes, dioxazine-series dyes, anthrapyrimidine-series dyes, anthanthrone-series dyes, indanthrone-series dyes, flavanthrone-series dyes, pyranthrone-series dyes, perynone-series dyes, perylene-series dyes, and thioindigo-series dyes; X represents —CO—, —CONH—Y2—, —SO2NH—Y2—, or —CH2NHCOCH2NH—Y2— (Y2 represents an alkylene group or an arylene group, each of which may be substituted); Y1 represents —NH— or —O—; Z represents a hydroxyl group or a group represented by formula (Ia) with the proviso that in the case where n is 1, Z may be —NH—X-Q; R1 and R2 each independently represent a substituted or unsubstituted alkyl group, alternatively, R1 and R2 represent groups that bond together to form a heterocyclic group which at least contains a nitrogen atom; m represents an integer of 1 to 6; and n represents an integer of 1 to 4;
wherein Y3 represents —NH— or —O—; and m, R1, and R2 have the same meanings as those in formula (I);
[Chemical formula 9]
A-N═N—X1—Y4 Formula (II)
wherein A represents a component capable of forming an azo dye together with X1—Y4; X1 represents a single bond, or a group selected from divalent connecting groups represented by structural formulae of formulae (i) to (v) set forth below; and Y4 represents a group represented by the following formula (III); and
wherein Z1 represents a lower alkylene group having 1 to 5 carbon atoms; —NR3 represents a lower alkylamino group having 1 to 4 carbon atoms, or a nitrogen-containing, 5- or 6-membered, saturated heterocyclic group; and a represents 1 or 2.
<12> A method of producing phthalocyanine-series pigment fine particles, the method comprising: dissolving a phthalocyanine-series pigment in a good solvent, to prepare a pigment solution; mixing the pigment solution with a solvent which is compatible with the good solvent but is a poor solvent for the phthalocyanine-series pigment, to form fine particles of the phthalocyanine-series pigment having a size in the order of nanometer; and adding a pigment-dispersing agent comprising a compound represented by the following formula (IV) to the mixed solution in which the organic particles have been formed:
wherein Me represents a methyl group.
<13> The method of producing phthalocyanine-series pigment fine particles according to the above item <11> or <12>, wherein the phthalocyanine-series pigment is Pigment Blue 15:6, Pigment Green 7, or Pigment Green 36.
The term “nano-size” means a size in the order of nanometer and specifically means a size of about 10 to 200 nm. Also, a fine particle having a nano-size particle diameter is also referred to as “nanoparticle”.
Other and further features and advantages of the invention will appear more fully from the following description, taking the accompanying drawings into consideration.
Symbols for principal elements in the figures are described below.
The present invention will be explained in detail.
No particular limitation is imposed on the phthalocyanine-series pigment insofar as it has a phthalocyanine structure. As the phthalocyanine-series pigment, for example, C.I. Pigment Green 7 (C.I. No. 74260), C.I. Pigment Green 36 (C.I. No. 74265), Pigment Green 37 (C.I. No. 74255), Pigment Blue 16 (C.I. No. 74100), C.I. Pigment Blue 75 (C.I. No. 74160:2) or 15:6 (C.I. No. 74160) or the like is preferably used. In addition to these, examples of the phthalocyanine-series pigments for color filter also include the pigments described in “Dictionary of Pigments”, Sep. 25, 2000, published by Asakura Publishing Company Ltd., pp. 300 to 314; and among them, pigment blue 15:6, pigment green 7, and pigment green 36 are favorable from the point of absorption spectrum.
The pigment dispersion composition, in which the phthalocyanine-series pigment fine particles of the present invention are dispersed (hereinafter, referred to simply as “pigment dispersion composition of the present invention”), may be in a form of a mixture which contains any one or more of these phthalocyanine-series pigments and any one or more of perylene, perinone, quinacridone, quinacridone quinone, anthraquinone, anthoanthrone, benzimidazolone, disazo-condensate, disao, azo, indanthrone, phthalocyanine, triarylcarbonium, dioxazine, aminoanthraquinone, diketo pyrrolopyrrole, thioindigo, isoindoline, isoindolinone, pyranthrone, or isoviolanthrone-series pigments.
Examples of a pigment that can be used in combination with the phthalocyanine-series pigment include:
perylene-series pigments, such as C.I. Pigment Red 190 (C.I. No. 71140), C.I. Pigment Red 224 (C.I. No. 71127), C.I. Pigment Violet 29 (C.I. No. 71129), or the like; perynone-series pigments, such as C.I. Pigment Orange 43 (C.I. No. 71105), C.I. Pigment Red 194 (C.I. No. 71100) or the like;
quinacridone-series pigments, such as C.I. Pigment Violet 19 (C.I. No. 73900), C.I. Pigment Violet 42, C.I. Pigment Red 122 (C.I. No. 73915), C.I. Pigment Red 192, C.I. Pigment Red 202 (C.I. No. 73907), C.I. Pigment Red 207 (C.I. Nos. 73900/73906), C.I. Pigment Red 209 (C.I. No. 73905) or the like;
quinacridonequinone-series pigments, such as C.I. Pigment Red 206 (C.I. No. 73900/73920), C.I. Pigment Orange 48 (C.I. No. 73900/73920), C.I. Pigment Orange 49 (C.I. No. 73900/73920), or the like;
anthraquinone-series pigments, such as C.I. Pigment Yellow 147 (C.I. No. 60645) or the like;
anthanthrone-series pigments, such as C.I. Pigment Red 168 (C.I. No. 59300) or the like;
benzimidazolone-series pigments, such as C.I. Pigment Brown 25 (C.I. No. 12510), C.I. Pigment Violet 32 (C.I. No. 12517), C.I. Pigment Yellow 180 (C.I. No. 21290), C.I. Pigment Yellow 181 (C.I. No. 11777), C.I. Pigment Orange 62 (C.I. No. 11775), C.I. Pigment Red 185 (C.I. No. 12516), or the like;
condensed disazo-series pigments, such as C.I. Pigment Yellow 93 (C.I. No. 20710), C.I. Pigment Yellow 94 (C.I. No. 20038), C.I. Pigment Yellow 95 (C.I. No. 20034), C.I. Pigment Yellow 128 (C.I. No. 20037), C.I. Pigment Yellow 166 (C.I. No. 20035), C.I. Pigment Orange 34 (C.I. No. 21115), C.I. Pigment Orange 13 (C.I. No. 21110), C.I. Pigment Orange 31 (C.I. No. 20050), C.I. Pigment Red 144 (C.I. No. 20735), C.I. Pigment Red 166 (C.I. No. 20730), C.I. Pigment Red 220 (C.I. No. 20055), C.I. Pigment Red 221 (C.I. No. 20065), C.I. Pigment Red 242 (C.I. No. 20067), C.I. Pigment Red 248, C.I. Pigment Red 262, C.I. Pigment Brown 23 (C.I. No. 20060), or the like;
disazo-series pigments, such as C.I. Pigment Yellow 13 (C.I. No. 21100), C.I. Pigment Yellow 83 (C.I. No. 21108), C.I. Pigment Yellow 188 (C.I. No. 21094), or the like;
azo-series pigments, such as C.I. Pigment Red 187 (C.I. No. 12486), C.I. Pigment Red 170 (C.I. No. 12475), C.I. Pigment Yellow 74 (C.I. No. 11714), C.I. Pigment Yellow 150 (C.I. No. 48545), C.I. Pigment Red 48 (C.I. No. 15865), C.I. Pigment Red 53 (C.I. No. 15585), C.I. Pigment Orange 64 (C.I. No. 12760), C.I. Pigment Red 247 (C.I. No. 15915), or the like;
indanthrone-series pigments, such as C.I. Pigment Blue 60 (C.I. No. 69800), or the like; phthalocyanine-series pigments, such as C.I. Pigment Green 7 (C.I. No. 74260), C.I. Pigment Green 36 (C.I. No. 74265), C.I. Pigment Green 37 (C.I. No. 74255), C.I. Pigment Blue 16 (C.I. No. 74100), C.I. Pigment Blue 75 (C.I. No. 74160:2), C.I. Pigment Blue 15:6 (C.I. No. 74160), C.I. Pigment Blue 15:3 (C.I. No. 74160), or the like;
triaryl carbonium-series pigments, such as C.I. Pigment Blue 56 (C.I. No. 42800), C.I. Pigment Blue 61 (C.I. No. 42765:1), or the like;
dioxazineseries pigments, such as C.I. Pigment Violet 23 (C.I. No. 51319), C.I. Pigment Violet 37 (C.I. No. 51345), or the like;
aminoanthraquinone-series pigments, such as C.I. Pigment Red 177 (C.I. No. 65300), or the like;
diketopyinolopyrrole-series pigments, such as C.I. Pigment Red 254 (C.I. No. 56110), C.I. Pigment Red 255 (C.I. No. 561050), C.I. Pigment Red 264, C.I. Pigment Red 272 (C.I. No. 561150), C.I. Pigment Orange 71, C.I. Pigment Orange 73, or the like; thioindigo-series pigments, such as C.I. Pigment Red 88 (C.I. No. 73312), or the like; isoindoline-series pigments, such as C.I. Pigment Yellow 139 (C.I. No. 56298), C.I. Pigment Yellow 185, C.I. Pigment Orange 66 (C.I. No. 48210), or the like;
isoindolinone-series pigments, such as C.I. Pigment Yellow 109 (C.I. No. 56284), C.I. Pigment Yellow 185 (C.I. No. 56290), C.I. Pigment Orange 61 (C.I. No. 11295), or the like;
pyranthrone-series pigments, such as C.I. Pigment Orange 40 (C.I. No. 59700), C.I. Pigment Red 216 (C.I. No. 59710), or the like;
quinophthalone-based pigments, such as C.I. Pigment Yellow 138, or the like; and isoviolanthrone-series pigments, such as C.I. Pigment Violet 31 (C.I. No. 60010).
Hereinafter, the phthalocyanine-series pigments and pigments used together are collectively called as “organic pigment”.
In the pigment dispersion composition of the present invention, two or more organic pigments or solid solutions of organic pigment may be used in combination, or alternatively, a pigment may be used in combination with a common dye.
The dye that can be used in the present invention is not particularly limited, and dye commonly used for color filters may be used. Examples thereof include dyes disclosed in, for example, JP-A-64-90403, JP-A-64-91102, JP-A-1-94301, JP-A-6-11614, Japanese Patent No. 2592207, U.S. Pat. No. 4,808,501, U.S. Pat. No. 5,667,920, U.S. Pat. No. 5,059,500, JP-A-5-333207, JP-A-6-35183, JP-A-6-51115, JP-A-6-194828, JP-A-8-211599, JP-A-4-249549, JP-A-10-123316, JP-A-11-302283, JP-A-7-286107, JP-A-2001-4823, JP-A-8-15522, JP-A-8-29771, JP-A-8-146215, JP-A-11-343437, JP-A-8-62416, JP-A-2002-14220, JP-A-2002-14221, JP-A-2002-14222, JP-A-2002-14223, JP-A-8-302224, JP-A-8-73758, JP-A-8-179120 and JP-A-8-151531.
Various dyes different in chemical structure, such as pyrazole azo dyes, anilino azo dyes, triphenylmethane dyes, anthraquinone dyes, anthrapyridone dyes, benzylidene dyes, oxonol dyes, pyrazolotriazole azo dyes, pyridone azo dyes, cyanine dyes, phenothiazine dyes, pyrrolopyrazole azomethine dyes, xanthene dyes, phthalocyanine dyes, benzopyran dyes, and indigo dyes, may be used.
Further, in a case of a resist system in which development is performed in water or an alkaline solution, an acid dye and/or a derivative thereof may favorably be used from the viewpoint of completely removing the binder and/or the dye in a light-unirradiated portion by the development.
Further, for example, a direct dye, a basic dye, a mordant dye, an acid mordant dye, an azoic dye, a disperse dye, an oil-soluble dye, a dye for food and/or derivatives thereof may also be usefully used.
The acid dye is not particularly limited, so long as it is a dye having an acidic group such as, for example, a sulfonic acid and a carboxylic acid. However, it is necessary to select the acid dye by taking into consideration all of required properties, such as solubility against an organic solvent or a developer, formability of a salt with a basic compound, light absorbance, an interaction with any one of other components in the composition, light resistance and heat resistance.
Specific examples of the above-described acid dye are described below, but the present invention is not restricted to these examples. Examples thereof include Acid Alizarin Violet N; Acid Black 1, 2, 24, 48; Acid Blue 1, 7, 9, 15, 18, 23, 25, 27, 29, 40, 45, 62, 70, 74, 80, 83, 86, 87, 90, 92, 103, 112, 113, 120, 129, 138, 147, 158, 171, 182, 192, 243 and 324:1; Acid Chrome Violet K; Acid Fuchsin; Acid Green 1, 3, 5, 9, 16, 25, 27 and 50; Acid Orange 6, 7, 8, 10, 12, 50, 51, 52, 56, 63, 74 and 95; Acid Red 1, 4, 8, 14, 17, 18, 26, 27, 29, 31, 34, 35, 37, 42, 44, 50, 51, 52, 57, 66, 73, 80, 87, 88, 91, 92, 94, 97, 103, 111, 114, 129, 133, 134, 138, 143, 145, 150, 151, 158, 176, 183, 198, 211, 215, 216, 217, 249, 252, 257, 260, 266 and 274; Acid Violet 6B, 7, 9, 17 and 19; Acid Yellow 1, 3, 7, 9, 11, 17, 23, 25, 29, 34, 36, 42, 54, 72, 73, 76, 79, 98, 99, 111, 112, 114, 116, 184, and 243; Food Yellow 3; and derivatives of theses dyes.
In addition to the above dyes, acid dyes such as azo type, xanthene type and phthalocyanine type dyes are preferable, and acid dyes such as C.I. solvent Blue 44 and 38; C.I. Solvent Orange 45; Rhodamine B; Rhodamine 110; and derivatives thereof are preferably used.
Examples of the organic dye include an azo dye, a cyanine dye, a merocyanine dye and a coumarin dye. Examples of the polymer compound include polydiacetylene and polyimide.
In the pigment dispersion composition of the present invention, two or more organic pigments or solid solutions of organic pigment may be used in combination.
Next, the good solvent in the formation of nano-sized phthalocyanine pigment fine particles will be explained.
The good solvent is not particularly limited as long as it can dissolve the organic pigment to be used, and is compatible, or uniformly mixed, with the poor solvent to be used at the time of the production of the organic pigment particles. With respect to the solubility of the organic pigment in the good solvent, the solubility of the organic pigment is preferably 0.2 mass % or more, and more preferably 0.5 mass % or more. The solubility of the organic pigment in the good solvent has no particular upper limit, but it is practical that the solubility is 50 mass % or less in consideration of an organic pigment to be ordinarily used. The solubility may be solubility in the case where the organic pigment is dissolved in the presence of an acid or an alkali or under pressure. Further, compatibility or uniform mixing property between the good solvent and the poor solvent is such that the solubility of the good solvent in the poor solvent is preferably 30 mass % or more, more preferably 50 mass % or more. The solubility of the good solvent in the poor solvent has no particular upper limit, but it is practical that the solvents can mix with each other at an arbitrary ratio.
Examples of the good solvents include aqueous solvents (e.g., water, hydrochloric acid, and aqueous sodium hydroxide solution), alcohol-series solvents, amide-series solvents, ketone-series solvents, ether-series solvents, aromatic solvents, carbon disulfide, aliphatic solvents, nitrile-series solvents, sulfoxide-series solvents, halogen-containing solvents, ester-series solvents, ionic liquids, mixed solvents thereof, and the like. Among these, aqueous solvents, alcohol-series solvents, ester-series solvents, sulfoxide-series solvents, and amide-series solvents are preferable; aqueous solvents, sulfoxide-series solvents, and amide-series solvents are more preferable; and sulfoxide-series solvents, and amide-series solvents are particularly preferable.
Examples of the alcohol-series solvents include methanol, ethanol, isopropyl alcohol, n-propyl alcohol, and 1-methoxy-2-propanol. Examples of the amide-series solvents include N,N-dimethylformamide, 1-methyl-2-pyrrolidone, 2-pyrrolidinone, 1,3-dimethyl-2-imidazolidinone, 2-pyrroridinone, ε-caprolactam, formamide, N-methylformamide, acetamide, N-methylacetamide, N,N-dimethylacetamide, N-methylpropaneamide, and hexamethylphosphoric triamide. Examples of the ketone-series solvents include acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone. Examples of ether-series solvents include dimethylether, diethylether and tetrahydrofuran. Examples of the aromatic solvents include benzene and toluene. Examples of the aliphatic solvents include hexane, and the like. Examples of the nitrile-series solvents include acetonitrile, and the like. Examples of the sulfoxide-series solvents include dimethyl sulfoxide, diethyl sulfoxide, hexamethylene sulfoxide, and sulfolane. Examples of the halogen-containing solvents include dichloromethane and trichloroethylene. Examples of the ester-series solvents include ethyl acetate, ethyl lactate and 2-(1-methoxy)propyl acetate. Examples of the ionic liquids include a salt of 1-butyl-3-methylimidazolium and PF6−, and the like.
Further, the concentration of the organic pigment solution prepared by dissolving the organic pigment in the good solvent is preferably in the range of from the saturation concentration of the organic pigment with respect to the good solvent under a condition at the time of the dissolution to about one hundredth of the saturation concentration.
With regard to the condition of the preparation of the organic pigment solution, there is no particular limitation to the condition of the preparation of the organic pigment solution, and a selection may be made from a range from normal pressure, subcritical or supercritical condition. The organic pigment is preferably dissolved under pressure and more preferably under a pressure of 105 to 108 Pa in view of yield improvement. The temperature in the case where solution is prepared under normal pressure is preferably −10 to 150° C., more preferably −5 to 130° C. and even more preferably 0 to 100° C.
In the present invention, at the time of producing the pigment dispersion composition, it is necessary that the organic pigment contained in the organic pigment solution to be used be uniformly dissolved in the good solvent, and further it is preferred that the organic pigment be dissolved when the solvent is acidic or alkaline In general, in the case of a pigment having in the molecule thereof a group dissociative under alkaline conditions, an alkaline solvent is used, and in the case of a pigment having no group dissociative under alkaline conditions but having in the molecule thereof many nitrogen atoms, to which protons easily adhere, an acidic solvent is used. For example, quinacridone-, diketopyrrolopyrrole-, and condensed disazo-series pigments are dissolved in alkaline conditions, while phthalocyanine-series pigments are dissolved in acidic conditions.
Examples of a base that can be used in the case that the pigment is dissolved in the alkaline condition, include inorganic bases, such as lithium hydroxide, sodium hydroxide, potassium hydroxide, calcium hydroxide, and barium hydroxide; and organic bases, such as trialkylamine, diazabicycloundecene (DBU), and metal alkoxides. An inorganic base is preferred.
The amount of the base to be used is not particularly limited, as long as the base in the amount can homogeneously dissolve the pigment. In the case of the inorganic base, the amount thereof is preferably from 1.0 to 30 mole equivalents, more preferably from 1.0 to 25 mole equivalents, and further preferably from 1.0 to 20 mole equivalents, to the organic pigment. In the case of the organic base, the amount thereof is preferably from 1.0 to 100 mole equivalents, more preferably from 5.0 to 100 mole equivalents, and further preferably from 20 to 100 mole equivalents, to the organic pigment.
Examples of an acid to be used in the case that the pigment is dissolved in the acidic condition, include inorganic acids, such as sulfuric acid, hydrochloric acid, and phosphoric acid; and organic acids, such as acetic acid, trifluoroacetic acid, oxalic acid, methanesulfonic acid, and trifluoromethanesulfonic acid. Among these, the inorganic acids are preferable, and sulfuric acid is especially preferable.
The amount of the acid to be used is not particularly limited, as long as the acid in the amount can homogenously dissolve the organic pigment. In many cases, the acid is used in a larger or more excessive amount than the base. Regardless the kind of the acid being an inorganic acid or an organic acid, the amount of the acid to be used is preferably from 3 to 500 mole equivalents, more preferably from 10 to 500 mole equivalents, and further preferably from 30 to 200 mole equivalents, to the organic pigment.
Next, a preferable poor solvent at the time of formation of phthalocyanine type pigment fine particles will be explained.
For the poor solvent, there is no particular limitation as long as the poor solvent does not dissolve an organic pigment to be used, and the poor solvent is compatible or uniformly mixed with the good solvent to be used at the time of the production of the organic pigment particles. The solubility of the organic material in the poor solvent is preferably 0.02 mass % or less, more preferably 0.01 mass % or less. A preferable range for compatibility or uniform mixing property between the poor solvent and the good solvent is as described above.
Examples of the poor solvents include aqueous solvents (e.g., water, hydrochloric acid, and aqueous sodium hydroxide solution), alcohol-series solvents, ketone-series solvents, ether-series solvents, aromatic solvents, carbon disulfide, aliphatic solvents, nitrile-series solvents, halogen-containing solvents, ester-series solvents, ionic liquids, and mixed solvents thereof. Preferable poor solvents include aqueous solvents, alcohol-series solvents and ester-series solvents.
Examples of the alcohol-series solvents include methanol, ethanol, isopropyl alcohol, n-propyl alcohol, and 1-methoxy-2-propanol. Examples of the ketone-series solvents include acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone. Examples of the ether-series solvents include dimethylether, diethylether and tetrahydrofuran. Examples of the aromatic solvents include benzene and toluene. Examples of the aliphatic solvents include hexane, and the like. Examples of the nitrile-series solvents include acetonitrile, and the like. Examples of the halogen-containing solvents include dichloromethane and trichloroethylene. Examples of the ester-series solvents include ethyl acetate, ethyl lactate and 2-(1-methoxy)propyl acetate. Examples of the ionic liquids include a salt of 1-butyl-3-methylimidazolium and PF6−, and the like.
The above-described examples of the good solvent and those of the poor solvents overlap, but the identical solvent is not selected for both the good solvent and the poor solvent. Any solvents may be used in combination of them as long as an organic material to be used shows solubility in the good solvent sufficiently higher than that in the poor solvent. Specifically, the difference in solubility between them is preferably 0.2 mass % or more, and more preferably 0.5 mass % or more. There is no particular upper limit to the difference in solubility between the good solvent and the poor solvent. However, if ordinarily used organic materials are taken into consideration, it is practical that the upper limit is 50 mass % or less.
When the pigment dispersion composition of the present invention is produced, it is preferable to add a binder having an acid group when the organic nanoparticles are formed. The binder may be added to both or one of the organic pigment solution and the poor solvent which is to be used to form organic nanoparticles by adding thereto the organic pigment solution. It is also preferable to add a binder solution, which is independently prepared, at the time of the formation of the organic nanoparticles. The binder that can be used in the method of producing pigment dispersion composition of the present invention is preferably an alkali-soluble polymer having a polar group such as a carboxylic acid group or a carboxylate group at its side chain. Examples thereof include a methacrylic acid copolymer, an acrylic acid copolymer, an itaconic acid copolymer, a crotonic acid copolymer, a maleic acid copolymer, and a partially-esterified maleic acid copolymer, as described in JP-A-59-44615, JP-B-54-34327 (“JP-B” means examined Japanese patent publication), JP-B-58-12577, JP-B-54-25957, JP-A-59-53836, and JP-A-59-71048. The examples further include a cellulose derivative having a carboxylic acid group, a carboxylate group or the like at its side chain. In addition to the foregoing, a product obtained by adding a cyclic acid anhydride to a polymer having a hydroxyl group can also be preferably used. In addition, particularly preferable examples of the binder include a copolymer of benzyl(meth)acrylate and (meth)acrylic acid and a multi-component copolymer of benzyl(meth)acrylate, (meth)acrylic acid, and any other monomer described in U.S. Pat. No. 4,139,391. These binder polymers having a polar group may be used singly or in the form of a composition containing the binder polymer together with an ordinary film-forming polymer. The addition amount of the binder polymer is generally from 10 to 200 mass parts, preferably from 25 to 100 mass parts, based on 100 mass parts of the organic pigment.
Further, for the purpose of improving crosslinking efficiency, a polymerizable group may be included in the side chain, and ultraviolet curing resins and thermosetting resins are also useful. Examples of the polymers containing polymerizable groups are given below, but not limited to these, provided that an alkali soluble group, such as —COOH group, —OH group, and an ammonium group, and a carbon-carbon unsaturated bond, are included therein. For example, a compound which is obtained by reacting a compound having an epoxy ring, which has a reactivity with —OH group, and a carbon-carbon unsaturated bond group, such as glycidyl acrylate, with a copolymer which is composed of a monomer having —OH group, such as 2-hydroxyethylacrylate, a monomer having —COOH group, such as methacrylic acid, and a monomer which is copolymerizable with the forgoing two types of monomers, such as an acrylic compound, a vinyl-series compound or the like, can be used. As the compound having a reactivity with —OH group, a compound having an acryloyl group, and an acid anhydride, and an isocyanate group, in place of the epoxy ring, can be used. Further, a reaction product which is obtained by reacting a saturated- or unsaturated-polybasic acid anhydride with a compound obtained by reacting a compound having an epoxy ring with an unsaturated carboxylic acid, such as acrylic acid, as disclosed in JP-A-6-102669 and JP-A-6-1938 can also be used. Examples of the compound which has both an alkali-soluble group, such as a —COOH group, and a carbon-carbon unsaturated group include DIANAL NR series (manufactured by Mitsubishi Rayon Co., Ltd.), PHOTOMER 6173 (—COOH group-containing polyurethane acrylic oligomer, manufactured by Diamond Shamrock Co., Ltd.), VISCOAT R-264 and KS RESIST 106 (manufactured by Osaka Organic Chemical Industry Ltd.), CYCLOMER P series and PRAXEL CF200 series (manufactured by Daicel Chemical Industries, Ltd.), EBECRYL 3800 (manufactured by Daicel-UCB Company Ltd.), and the like.
Further as the binder resin, organic macromolecule polymers having a water-soluble atomic group at a part of side chains of the polymer can be used. It is preferable that the binder resin is a linear organic macromolecule polymer miscible with a monomer and is soluble in an organic solvent and an alkaline solution (preferably one developable with a weak alkaline aqueous solution). Examples of such an alkali-soluble resin include polymers which have a carboxylic acid in a side chain, such as the methacrylic acid copolymer, the acrylic acid copolymer, the itaconic acid copolymer, the crotonic acid copolymer, the maleic acid copolymer, the partially esterified maleic acid copolymer, and the like as disclosed in, for example, JP-A-59-44615, JP-B-54-34327, JP-B-58-12577, JP-B-54-25957, JP-A-59-53836, and JP-A-59-71048. Similarly, acidic cellulose derivatives which have a carboxylic acid in a side chain are useful. In addition to these, a polymer having a hydroxyl group to which an acid anhydride is added, and the like are also useful as the aforementioned alkali-soluble resin. Specifically, benzyl(meth)acrylate/(meth)acrylic acid copolymers and multi-component copolymers of benzyl(meth)acrylate/(meth)acrylic acid/other monomer are particularly preferred among these polymers. As the above-described alkali-soluble resin, use can be made of a copolymer (hereinafter sometimes referred to as “copolymer A”) composed of at least (i) at least one kind of acid component monomer selected from maleic acid anhydride (MAA), acrylic acid (AA), methacrylic acid (MA), and fumaric acid (FA), and (ii) alkylpolyoxyethylene (meth)acrylate, and (iii) benzyl(meth)acrylate.
As the combination of the components in the above-described copolymer A, a composition ratio by mass of (i) an acid component monomer, (ii) alkylpolyoxyethylene (meth)acrylate (Acr(EO)n: CH3(OC2H4)nOCOC(R)═CH2), and (iii) benzyl(meth)acrylate (Bz(M)A) is preferably 10-25/5-25/50-85, and more preferably 15-20/5-20/60-80. Besides, a weight average molecular weight (Mw) of the above-described copolymer in terms of polystyrene, according to GPC is preferably in the range of from 3,000 to 50,000, and more preferably from 5,000 to 30,000.
If the composition ratio by mass of (i) an acid component monomer is in the above-described range, alkali solubility and dissolution properties to solvents hardly decrease. Besides, if the composition ratio by mass of (ii) alkylpolyoxyethylene (meth)acrylate (Acr(EO)n: CH3(OC2H4)nOCOC(R)═CH2) is in the above-described range, a solution of the composition is easily spread onto a substrate, and also dispersibility of the coloring agent hardly decrease. Therefore, effects of the present invention can be effectively attained. If the composition ratio by mass of (iii) benzyl (meth)acrylate (Bz(M)A) is in the above-described range dispersion stability of the coloring agent, solubility of the coloring agent in a composition, and alkaline development suitability of the coating film hardly decrease.
The repeating number n of polyoxyethylene (EO)n in (ii) alkylpolyoxyethylene (meth)acrylate (Acr(EO)n: CH3(OC2H4)nOCOC(R)═CH2) is preferably in the range of from 2 to 15, more preferably from 2 to 10, and especially preferably from 4 to 10. If the repeating number n is in the above-described range, a development residue hardly generates after development with an alkaline developer. In addition, such the range can prevent generation of coating unevenness that is caused by reduction in fluidity of the composition as a coating solution. Consequently, said range can prevent deterioration in both uniformity of the coating film thickness and saving of liquid.
These binder polymers having a polar group may be used singly or in the form of a composition containing the binder polymer together with an ordinary film-forming polymer. The addition amount of the binder polymer is generally from 10 to 200 mass parts, preferably from 25 to 100 mass parts, based on 100 mass parts of the organic pigment.
In the case where the binder is a polymer compound, the number of acid groups in the polymer compound is not particularly limited; but the number of repeating units each having an acid group(s) is preferably 5 to 100, and more preferably 10 to 100, when the number of repeating units in one molecule is set to 100. In addition, the polymerization ratio between (1) a repeating unit derived from a compound having a carboxyl group and (2) a repeating unit derived from a compound having a carboxylate group is preferably as follows: a ratio of the repeating unit (1) is 5 to 40 mol %, a ratio of the repeating unit (2) is 40 to 90 mol %, and a ratio of a repeating unit(s) except the repeating units (1) and (2) is 25 mol % or less. In addition, the molecular weight of the alkali-soluble binder polymer compound having an acid group is preferably 3,000 to 1,000,000, more preferably 4,000 to 200,000, and particularly preferably 5,000 to 80,000.
In the method of producing a pigment dispersion composition of the present invention, a dispersing agent may be added to one or both of the organic pigment solution and the poor solvent to which the organic pigment solution is to be added to form organic nanoparticles. Alternatively, it is also preferred to add a dispersing agent solution in a route separate from the above-described two solutions at the time when the organic nanoparticles are prepared. The dispersing agent has a function (1) that the dispersing agent is rapidly adsorbed on the surface of the formed pigment, to form fine pigment particles, and (2) that these particles are prevented from aggregating again.
As the dispersing agent, use can be made of a pigment-derivative-type, and low-molecular-weight or polymer dispersing agent. The molecular weight of the polymer dispersing agent for use may be any value, as long as the dispersing agent can be uniformly dissolved in a solution, but the polymer dispersing agent preferably has a molecular weight of 1,000 to 2,000,000, more preferably of 5,000 to 1,000,000, still more preferably of 10,000 to 500,000, and particularly preferably of 10,000 to 100,000. (Concerning the present specification, the term “molecular weight” means a weight-average molecular weight, unless otherwise stated. Polymer compounds are polydispersion-series compounds and do not always have a single molecular weight or a single particle mass. Thus, their measured molecular weights should be represented by a certain type of average molecular weight. The three main types of the average molecular weight are: 1) number average molecular weight Mn, 2) weight-average molecular weight Mw and 3) Z average molecular weight Mz; and the relationship Mn<Mw<Mz can be established.) Examples of the polymer dispersing agent include polyvinyl pyrrolidone, polyvinyl alcohol, polyvinyl methyl ether, polyethylene oxide, polyethylene glycol, polypropylene glycol, polyacrylamide, vinyl alcohol/vinyl acetate copolymer, partial-formal products of polyvinyl alcohol, partial-butyral products of polyvinyl alcohol, vinylpyrrolidone/vinyl acetate copolymer, polyethylene oxide/propylene oxide block copolymer, polyacrylic acid salts, polyvinyl sulfuric acid salts, poly(4-vinylpyridine) salts, polyamides, polyallylamine salts, condensed naphthalenesulfonic acid salts, cellulose derivatives, and starch derivatives. Besides, natural polymers can be used, examples of which include alginic acid salts, gelatin, albumin, casein, gum arabic, tragacanth gum, and ligninsulfonic acid salts. Above all, it is preferred to use polyvinyl pyrrolidone. These polymers may be used singly or in combination of two or more. These dispersing agents may be used singly or in combination of two or more thereof. The dispersing agents to be used when dispersing a pigment are described in detail in “Dispersion Stabilization of Pigment and Surface Treatment Technique/Evaluation” (published by Japan Association for International Chemical Information, on December 2001), pp. 29-46.
Examples of the anionic dispersing agent (anionic surfactant) include N-acyl-N-alkyltaurine salts, fatty acid salts, alkylsulfates, alkylbenzenesulfonates, alkylnaphthalenesulfonates, dialkylsulfosuccinates, alkylphosphates, naphthalenesulfonic acid/formalin condensates, and polyoxyethylenealkylsulfates. Among these, N-acyl-N-alkyltaurine salts are particularly preferable. As the N-acyl-N-alkyltaurine salts, those described in JP-A-3-273067 are preferable. These anionic dispersing agents may be used singly or in combination of two or more thereof.
Examples of the cationic dispersing agent (cationic surfactant) include quaternary ammonium salts, alkoxylated polyamines, aliphatic amine polyglycol ethers, aliphatic amines, diamines and polyamines derived from aliphatic amine and aliphatic alcohol; imidazolines derived from aliphatic acid, and salts of these cationic substances. These cationic dispersing agents may be used singly or in combination of two or more thereof.
The amphoteric dispersing agent is a dispersing agent having, in the molecule thereof, an anionic group moiety which the anionic dispersing agent has in the molecule and a cationic group moiety which the cationic dispersing agent has in the molecule.
Examples of the nonionic dispersing agents (nonionic surfactant) include polyoxyethylenealkyl ethers, polyoxyethylenealkylaryl ethers, polyoxyethylene fatty acid esters, sorbitan fatty acid esters, polyoxyethylenesorbitan fatty acid esters, polyoxyethylenealkylamines, and glycerin fatty acid esters. Among these, polyoxyethylenealkyl ethers are preferable. These nonionic dispersing agents may be used singly or in combination of two or more thereof.
The pigment-derivative-type dispersing agent is defined as a dispersing agent that is derived from an organic pigment as a parent material and prepared by chemically modifying a structure of the parent material or that is obtained by a pigment-forming reaction of a chemically-modified pigment precursor. Examples of the pigment-derivative-type dispersing agent include sugar-containing pigment-derivative-type dispersing agents, piperidyl-containing pigment-derivative-type dispersing agents, naphthalene- or perylene-derivative pigment-derivative-type dispersing agents, pigment-derivative-type dispersing agents having a functional group linked through a methylene group to a pigment parent structure, pigment-derivative-type dispersing agents parent structure) chemically modified with a polymer, pigment-derivative-type dispersing agents having a sulfonic acid group, pigment-derivative-type dispersing agents having a sulfonamido group, pigment-derivative-type dispersing agents having an ether group, and pigment-derivative-type dispersing agents having a carboxylic acid group, carboxylate group, or carboxamido group.
Also, the compound represented by the formula (I) as described in the JP-A-2000-239554 is preferably used.
In the production method of the present invention, it is preferred that a phthalocyanine-series pigment is dissolved in a good solvent to which a pigment-dispersing agent comprising a compound represented by the following formula (I) or (II) is added, to prepare a pigment solution, then the pigment solution is mixed in a solvent which is compatible with the above good solvent and is a poor solvent for the above phthalocyanine-scries pigment, to form nano-size fine particles of the phthalocyanine-series pigment.
In formula (I), Q represents a residue of an organic dye selected from anthraquinone-series dyes, azo-series dyes, phthalocyanine-series dyes, quinacridone-series dyes, dioxazine-series dyes, anthrapyrimidine-series dyes, anthanthrone-series dyes, indanthrone-series dyes, flavanthrone-series dyes, pyranthrone-series dyes, perynone-series dyes, perylene-series dyes, and thioindigo-series dyes. Among these organic dyes, preferred are azo-series dyes and dioxazine-series dyes. The azo-series dyes are more preferred.
X represents —CO—, —CONH—Y2—, —SO2NH—Y2—, or —CH2NHCOCH2NH—Y2—. X is preferably —CO— or —CONH—Y2—.
Y2 represents an alkylene group or an arylene group, each of which may be substituted. Among these groups, preferred are a phenylene group, a toluoylene group, and a hexylene group. The phenylene group is more preferred.
Y1 represents —NH— or —O—.
Z represents a hydroxyl group or a group represented by formula (Ia) with the proviso that in the case where n is 1, Z may be —NH—X-Q.
In formula (Ia), Y3 represents —NH— or —O—, and m, R1, and R2 have the same meanings as those in formula (I).
R1 and R2 each independently represent a substituted or unsubstituted alkyl group, alternatively, R1 and R2 may be bonded together to form a heterocyclic group which at least contains a nitrogen atom. Among these groups, preferred are a methyl group, an ethyl group, a propyl group, and a pyrrolidinyl group which contains a nitrogen atom. The ethyl group is more preferred.
m represents an integer of 1 to 6, and preferably 2 or 3. n represents an integer of 1 to 4, and preferably 1 or 2.
The compounds represented by formula (I) are specifically represented, for example, by the following formulae.
In formulas (I-1) to (I-6), Q, m, n, R1, and R2 have the same meanings as those in formula (I). Specific examples of the compound represented by formula (I) are shown below, but the present invention is not meant to be limited to these.
The compounds represented by formula (I) can be obtained, for example, by reaction of a dye compound with an intermediate which is obtained by a reaction of a halogenated triazine compound with an amine compound having R1 and R2 and an alcohol compound having R1 and R2. The disclosure of the specification of JP-B-5-72943 can be also referred for the synthesis of the compound.
[Chemical formula 18]
A-N═N—X1—Y4 Formula (II)
In formula (II), A represents a component capable of forming an azo dye together with X1—Y4. The component A can be arbitrary selected as long as the component is capable of forming an azo dye upon coupling with a diazonium compound. Specific examples of the component A are shown below, but the present invention is not limited to these compounds.
In formula (II), X1 represents a single bond, or a group selected from divalent connecting groups represented by structural formulae of formulae (i) to (v) set forth below.
In formula (II), Y4 represents a group represented by the following formula (III).
In formula (III), Z1 represents a lower alkylene group. In other words, Z1 can be expressed as —(CH2)b— wherein b represents an integer of from 1 to 5, and preferably 2 or 3. In formula (III), —NR3 represents a lower alkylamino group, or a nitrogen-containing, 5- or 6-membered, saturated heterocyclic group. In the case where said —NR3 represents a lower alkylamino group, the lower alkylamino group can be expressed as —N(CnH2n+1)2 wherein n represents an integer of from 1 to 4, and preferably 1 or 2. In the case where said —NR3 represents a nitrogen-containing, 5- or 6-membered, saturated heterocyclic group, the heterocyclic group is preferably any one of the heterocyclic groups shown by the following structural formulae.
Each of Z1 and —NR3 in the above-described formula (III) may optionally have a lower alkyl group or an alkoxy group, as a substituent. In the above-described formula (III), a represents 1 or 2, and preferably 2.
Specific examples of the compound represented by formula (II) are shown below, but the present invention is not limited to these examples.
The compound represented by formula (II) can be synthesized referring to the method described in, for example, JP-A-2000-239554.
In the method of producing phthalocyanine-series pigment fine particles of the present invention, a pigment dispersing agent containing a graft copolymer having a nitrogen atom and an ether group and also, if necessary, containing properly selected other component(s) is preferably used.
The above-described graft copolymer at least has a nitrogen atom and an ether group, and also may contain other monomers as a copolymer unit. Herein, the nitrogen atom may be present in either the main chain or side chains of the graft copolymer.
The weight-average molecular weight of the graft copolymer is preferably in a range of from 3,000 to 100,000, and more preferably in a range of from 5,000 to 50,000. If the weight-average molecular weight (Mw) is less than 3,000, it is difficult to prevent the pigment from aggregating, which sometimes results in elevation of viscosity. If the weight-average molecular weight is more than 100,000, solubility to an organic solvent becomes insufficient, which sometimes results in elevation of viscosity. The term “weight-average molecular weight” as used herein refers to the weight-average molecular weight measured by gel permeation chromatography (carrier: tetrahydrofuran) and calculated in terms of polystyrene.
It is preferred that the above-described graft copolymer contain as copolymer units, at least (i) a polymerizable oligomer having an ethylenically unsaturated double bond at a terminal, (ii) a nitrogen atom-containing monomer having a nitrogen atom and an ethylenically unsaturated double bond, and (iii) a polymerizable monomer having an ether group, and also, if necessary, contain (iv) other monomer(s).
The graft copolymer comprises the main chain having at least an ether group-containing side chain and nitrogen atoms and also comprises another side chain that is derived from a polymerizable oligomer and bonded to the main chain by graft copolymerization. The binding site between the main chain and each side chain is formed by the polymerization reaction of the ethylenically unsaturated double bond at the terminal of the polymerizable oligomer. If necessary, the main chain and/or the side chain may contain any other copolymerized monomer unit.
The graft copolymer can be formed by polymerization reaction between the ethylenically-unsaturated double bond at the terminal of the polymerizable oligomer, the ethylenically-unsaturated double bond of the nitrogen-containing monomer, and the polymerizable monomer having an ether group.
The content of each of the copolymer units in the graft copolymer is as follows: the content of (i) the polymerizable oligomer is preferably in the range of from 15 to 98 mass %, more preferably from 25 to 90 mass %, the content of (ii) the nitrogen atom-containing monomer is preferably in the range of from 1 to 40 mass %, more preferably from 5 to 30 mass %, and the content of (iii) the polymerizable monomer having an ether group is preferably in the range of from 1 to 70 mass %, more preferably from 5 to 60 mass %.
If the content of the polymerizable oligomer is less than 15 mass %, a stereo-repulsion effect that should be attained by a dispersing agent is hardly obtained, and it sometimes becomes difficult to prevent the pigment from aggregating. If the content of the polymerizable oligomer is more than 98 mass %, the ratio of the nitrogen-containing monomer relatively decreases so that adsorption capacity to the pigment is lowered, and dispersibility sometimes becomes insufficient. If the content of the nitrogen-containing monomer is less than 1 mass %, dispersibility sometimes becomes insufficient owing to reduction of the adsorption capacity to the pigment. If the content of the nitrogen-group-containing monomer is more than 40 mass %, the ratio of the polymerizable oligomer relatively decreases so that a stereo-repulsion effect that should be attained by a dispersing agent is hardly obtained, and it sometimes becomes difficult to sufficiently prevent the pigment from aggregating. If the content of the polymerizable monomer having an ether group is less than 1 mass %, development suitability at the time of production of color filters and the like sometimes become insufficient. If the content of the polymerizable monomer having an ether group is more than 70 mass %, a capacity as a dispersing agent sometimes reduces.
The polymerizable oligomer (hereinafter, sometimes also referred to as “macro monomer”) has a group having an ethylenically unsaturated double bond at one or both ends (terminals) thereof. Among the aforementioned polymerizable oligomers, it is preferred in the present invention that the oligomer has a group having an ethylenically unsaturated double bond at only one of the ends of the oligomer.
As the aforementioned oligomer, homopolymers or copolymers formed firom at least one monomer selected from such monomers as alkyl(meth)acrylates, hydroxyalkyl(meth)acrylates, styrene, acrylonitrile, vinyl acetate, and butadiene can be mentioned. Among these oligomers, preferred are homopolymers or copolymers of alkyl(meth)acrylates and polystyrene. In the present invention, these oligomers may be rer substituted. There is no particular limitation to the substituent; a halogen atom can be mentioned as an example of the substituent.
Preferred examples of the group having an ethylenically unsaturated double bond include a (meth)acryloyl group and a vinyl group. Among these groups, (meth)acryloyl group is especially preferred.
In the present invention, among these polymerizable oligomers, preferred are oligomers represented by formula (6) set forth below.
In the above-described formula (6), R61 and R63 each represent a hydrogen atom or a methyl group. R62 represents an alkylene group which has 1 to 8 carbon atoms and which may be substituted by an alcoholic hydroxyl group, and R62 preferably represents an alkylene group having 2 to 4 carbon atoms. Y represents a phenyl group, a phenyl group having an alkyl group having 1 to 4 carbon atoms, or —COOR64 (R64 represents an alkyl group which has 1 to 6 carbon atoms and which may be substituted by an alcoholic hydroxyl group or halogen atom; a phenyl group, or an aralkyl group having 7 to 10 carbon atoms); and Y preferably represents a phenyl group or —COOR164 (R164 represents an alkyl group which has 1 to 4 carbon atoms and which may be substituted with an alcoholic hydroxyl group). q represents a number of from 20 to 200. Specific examples of the polymerizable oligomer include poly-2-hydroxyethyl (meth)acrylate, polystyrene, poly-methyl(meth)acrylate, poly-n-butyl(meth)acrylate, poly-1-butyl(meth)acrylate, and copolymers of these. Among these polymers, preferred are polymers having a (meth)acryloyl group bonded to one terminal of the molecule.
The polymerizable oligomer may be a commercially available product, or may be appropriately synthesized. Examples of the commercially available product include: a single-terminal-methacryloylated polystyrene oligomer (Mn=6,000, trade name: AS-6, manufactured by TOAGOSEI CO., LTD.); a single-terminal-methacryloylated polymethyl methacrylate oligomer (Mn=6,000, trade name: AA-6, manufactured by TOAGOSEI CO., LTD.); a single-terminal-methacryloylated poly-n-butyl acrylate oligomer (Mn=6,000, trade name: AB-6, manufactured by TOAGOSET CO., LTD.); a single-terminal-methaeryloylated polymethyl methacrylate/2-hydroxyethyl methaerylate oligomer (Mn=7,000, trade name: AA-714, manufactured by TOAGOSEI CO., LTD.); a single-terminal-methacryloylated polybutyl methacrylate/2-hydroxyethyl methacrylate oligomer (Mn=7,000, trade name: 707 S, manufactured by TOAGOSEI CO., LTD.); and a single-terminal-methacryloylated poly-2-ethylhexyl methacrylate/2-hydroxyethyl methacrylate oligomer (Mn=7,000, trade name: AY-707 S or AY-714 S, manufactured by TOAGOSEI CO., LTD.).
A preferable specific example of the polymerizable oligomer in the present invention is at least one kind of an oligomer selected from a polymer of an alkyl (meth)acrylate and a copolymer of an alkyl(meth)acrylate and polystyrene, with the oligomer having a number average molecular weight of 1,000 to 20,000, and with the oligomer having a (meth)acryloyl group at a terminal.
As the nitrogen-atom-containing monomer, a preferable example is any one of the compounds represented by formula (2) set forth below.
In the above-described formula (2), R21 represents a hydrogen atom or a methyl group. R22 represents an alkylene group having 1 to 8 carbon atoms, preferably 1 to 6 carbon atoms, and especially preferably 2 to 3 carbon atoms.
X2 represents —N(R23)(R24), —R25N(R26)(R27), a pyrrolidino group, a pyrrolidyl group, a pyridyl group, a piperidino group, an imidazolyl group, a carbazoyl group, a triazolyl group, a tetrazolyl group or a morpholino group, wherein R23 and R24 each independently represent a hydrogen atom, an alkyl group having 1 to 6 carbon atoms, or a phenyl group. R25 represents an alkylene group having 1 to 6 carbon atoms, and R26 and R27 each represent a hydrogen atom, an alkyl group having 1 to 6 carbon atoms, or a phenyl group.
Among these, —N(R23)(R24) and —R25N(R26)(R27) are preferable. R23 and R24 of the —N(R23)(R24) are preferably a hydrogen atom, an alkyl group having 1 to 4 carbon atoms, or a phenyl group, and R25 of the —R25N(R26)(R27) is preferably an alkylene group having 2 to 6 carbon atoms, and R26 and R27 are preferably an alkyl group having 1 to 4 carbon atoms. Among the pyridyl group, a 4-pyridyl group, a 2-pyridyl group and the like are preferable. Among the piperidino group, a 1-piperidino group and the like are preferable. Among the pyrrolidyl group, a 2-pyrrolidyl group and the like are preferable. Among the morpholino group, a 4-morpholino group and the like are preferable. m and n each represent 1 or 0. The cases where m=1 and n=1 and where m=1 and n=0 are preferred. (The resultant monomers correspond to the monomers represented by formulae (3) and (4) set forth below.)
In the present invention, among the compounds represented by formula (2), preferred are at least one compound selected from the compounds represented by any one of formulas (3) to (5) set forth below.
In the above-described formula (3), R31 has the same meaning as R21. R32 has the same meaning as X22. X3 has the same meaning as X2.
In the above-described formula (4), R41 has the same meaning as R21. X4 has the same meaning as X2, and X4 is preferably —N(R43)(R44) (wherein R43 and R44 have the same meanings as R23 and R24), or —R45N(R46)(R47) (wherein R45, R46, and R47 have the same meaning as R25, R26, and R27).
In the above-described formula (5), R51 has the same meaning as R21. X5 represents a pyrrolidino group, a pyrrolidyl group, a pyridyl group, a piperidino group, an imidazolyl group, a carbazoyl group, a triazolyl group, a tetrazolyl group or a morpholino group.
Preferable examples of the compound represented by the above-described formula (2) include (meth)acrylamides such as dimethyl(meth)acrylamide, diethyl(meth)acrylamide, diisopropyl(meth)acrylamide, di-n-butyl(meth)acrylamide, di-i-butyl(meth)acrylamide, morpholino(meth)acrylamide, piperidino(meth)acrylamide, N-methyl-2-pyrrolidyl(meth)acrylamide, and N,N-methylphenyl(meth)acrylamide; aminoalkyl(meth)acrylamides such as 2-(N,N-dimethylamino)ethyl(meth)acrylamide, 2-(N,N-diethylamino)ethyl(meth)acrylamide, 3-(N,N-diethylamino) propyl(meth)acrylamide, 3-(N,N-dimethylamino)propyl(meth)acrylamide, 1-(N,N-dimethylamino)-1,1-dimethylmethyl(meth)acrylamide, and 6-(N,N-diethylaminohexyl (meth)acrylamide; and vinylpyridine, N-vinylimidazole, N-vinylcarbazole, N-vinyltriazole and vinyl tetrazole.
(iii) Polymerizable Monomer Having Ether Group
As the polymerizable monomer having an ether group, preferred are at least one compound selected from the compounds represented by formula (1) set forth below.
In the above formula (1), R11 represents a hydrogen atom or a methyl group. R12 represents an alkylene group having 1 to 8 carbon atoms, preferably an alkylene group having 1 to 6 carbon atoms, and more preferably an alkylene group having 2 to 3 carbon atoms. X1 represents —OR13 or —OCOR14. Herein, R13 represents a hydrogen atom, an alkyl group having 1 to 18 carbon atoms, a phenyl group, or a phenyl group substituted with an alkyl group having 1 to 18 carbon atoms. R14 represents an alkyl group having 1 to 18 carbon atoms. Also, 1 denotes a number of 2 to 200, preferably 5 to 100, and particularly preferably 10 to 100.
No particular restriction is imposed on the polymerizable monomer having an ether group as long as the monomer is polymerizable and has an ether group, and the monomer can be appropriately selected from ordinary monomers. Examples thereof include polyethylene glycol mono(meth)acrylate, polypropylene glycol mono(meth)acrylate, polyethylene glycol polypropylene glycol mono(meth)acrylate, and polytetramethylene glycol monomethacrylate. These materials may be commercially available products or may be those synthesized properly. Examples of these commercially available products include methoxypolyethylene glycol methacrylate (trade name: NK ESTER M-40G, M-90G, and M-230G (manufactured by Toagosei Co., Ltd.); trade name: BLENMER-PME-100, PME-200, PME-400, PME-1000, PME-2000, and PME-4000 (manufactured by Nippon Oil & Fats Co., Ltd.)), polyethylene glycol monomethacrylate (trade name: BLENMER-PE-90, PE-200, and PE-350 manufactured by Nippon Oil & Fats Co., Ltd.); polypropylene glycol monomethacrylate (trade name: BLENMER-PP-500, PP-800, and PP-1000 manufactured by Nippon Oil & Fats Co., Ltd.), polyethylene glycol polypropylene glycol monomethacrylate (trade name: BLENMER-70PEP-370B manufactured by Nippon Oil & Fats Co., Ltd.), polyethylene glycol polytetramethylene glycol monomethacrylate (trade name: BLENMER-55PET-800 manufactured by Nippon Oil & Fats Co., Ltd.), and polypropylene glycol polytetramethylene glycol monomethacrylate (trade name: BLENMER-NHK-5050 manufactured by Nippon Oil & Fats Co., Ltd.).
The above-described graft copolymers may contain, additionally, the above-described other monomer(s) as a copolymer unit. The other monomers are not particularly limited, and they can be properly selected in accordance with purposes. Examples of the other monomers include, aromatic vinyl compounds (e.g., styrene, α-methyl styrene, vinyl toluene), alkyl(meth)acrylates (e.g., methyl(meth)acrylate, ethyl (meth)acrylate, n-butyl(meth)acrylate, i-butyl(meth)acrylate), alkylaryl(meth)acrylates (e.g., benzyl(meth)acrylate), glycidyl(meth)acrylate, vinyl carboxylates (e.g., vinyl acetate, vinyl propionate), vinyl cyanides (e.g., (meth)acrylonitrile, α-chloro acrylonitrile), aliphatic conjugate dienes (e.g., 1,3-butadiene, isoprene), and (meth)acrylic acid. Among these monomers, preferred are unsaturated carboxylic acids, alkyl(meth)acrylates, alkylaryl(meth)acrylates, and vinyl carboxylates.
The content of the other monomers in the above-described graft copolymers is, for example, preferably in the range of from 5 to 70 mass %. If the content is less than 5 mass %, it sometimes becomes difficult to control physical properties of the coating film. If the content is more than 70 mass %, it sometimes becomes difficult for the graft copolymer to fully exhibit its capacity as a pigment dispersing agent.
Preferable specific examples of the graft copolymers include:
(1) A copolymer of N-vinylimidazole/polyethylene glycol mono(meth)acrylate/terminal-methacryloylated polymethyl(meth)acrylate,
(2) A copolymer of N-vinylcarbazole/polyethylene glycol mono(meth)acrylate/terminal-metbacryloylated polymethyl(meth)acrylate,
(3) A copolymer of N-vinyltriazole/polyethylene glycol mono(meth)acrylate/terminal-methacryloylated polymethyl(meth)acrylate,
(4) A copolymer of N-vinylimidazole/polyethylene glycol mono(meth)acrylate/terminal-methacryloylated polystyrene,
(5) A copolymer of N-vinylearbazole/polyethylene glycol mono(meth)acrylate/terminal-methaeryloylated polystyrene,
(6) A copolymer of N-vinylimidazole/polyethylene glycol mono(meth)acrylate/methyl (meth)acrylate/terminal-methacryloylated polystyrene,
(7) A copolymer of N-vinylimidazole/polyethylene glycol mono(meth)acrylate/benzyl (meth)acrylate/terminal-methacryloylated polystyrene,
(8) A copolymer of vinylpyridine/polyethylene glycol mono(meth)acrylate/teiminal-methacryloylated polymethyl(meth)acrylate,
(9) A copolymer of N,N-dimethyl-2-piperidylethyl acrylate/polyethylene glycol mono(meth)acrylate/terminal-methacryloylated polymethyl(meth)acrylate,
(10) A copolymer of 4-morpholinoethyl acrylate/polyethylene glycol mono(meth)acrylate/terminal-methaciyloylated polymethyl(meth)acrylate,
(1) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethyleneglycol mono(meth)acrylate/terminal-metlacryloylated polymethyl(meth)acrylate,
(12) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethyleneglycol mono(meth)acrylate/terminal-methacryloylated polystyrene,
(13) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethyleneglycol mono(meth)acrylate/methyl(meth)acrylate/terminal-methacryloylated polystyrene,
(14) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethyleneglycol mono(ineth)acrylate/a copolymer of terminal-methacryloylated methyl(meth)acrylate and 2-hydroxyethylmethacrylate,
(15) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethylene glycol mono(meth)acrylate/a copolymer of terminal-methacryloylated methyl methacrylate and 2-hydroxyethyl methacrylate,
(16) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethylene glycol mono(meth)acrylate/a copolymer of terminal-methacryloylated methyl methaerylate and 2-hydroxyethyl methacrylate,
(17) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polypropyleneglycol mono(meth)acrylate/terminal-methacryloylated polymethyl(meth)acrylate,
(18) A copolymer of 3-(N,N-dimethylamino)propylacryamide/polyethyleneglycol polypropyleneglycol mono(meth)acrylate/terminal-methacryloylated polymethyl (meth)acrylate,
(19) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polyethyleneglycol polytetramethyleneglycol mono(meth)acrylate/terminal-methacryloylated polymethyl (meth)acrylate, and
(20) A copolymer of 3-(N,N-dimethylamino)propylacrylamide/polypropyleneglycol polytetramethyleneglycol mono(meth)acrylate/terminal-methacryloylated polymethyl (meth)acrylate.
Among these copolymers, preferred are (11), (14), and (18). Particularly preferred is a compound represented by formula (IV) set forth below.
The above-described graft copolymers can be obtained by subjecting components that constitute units of the above-described copolymers to, for example, radical polymerization in a solvent. At the time of the radical polymerization, a radical polymerization initiator may be used. Further, there can be used a chain transfer agent (e.g., 2-mercapto ethanol and dodecyl mercaptan). A pigment-dispersing agent containing a graft copolymer can be also prepared with reference to descriptions of JP-A-2001-31885.
In order to further improve uniform dispersibility and preservability of the pigment, the content of the dispersing agent is preferably in the range of from 0.1 to 1,000 mass parts, more preferably from 1 to 500 mass parts, and furthermore preferably from 10 to 250 mass parts, based on 100 mass parts of the pigment. When the content is less than 0.1 mass parts, it sometimes causes no improvement in dispersion stability of the organic pigment fine particles.
Also, as another embodiment of the production method of the present invention, preferred is a method wherein a phthalocyanine-series pigment is dissolved, to prepare a pigment solution, and the pigment solution is then mixed with a solvent that is compatible with the above good solvent and is a poor solvent for the above phthalocyanine-series pigment, to form nano-size fine particles of the phthalocyanine-series pigment, and a compound represented by the formula (I), (II) or (IV) is added to the mixed liquid containing the thus-formed organic fine particles. Particularly, the produced fine particles may be once concentrated and then redispersed; and it is preferred to use these compounds at the time of redispersing the produced fine particles.
The condition under which the organic pigment is prepared as organic nanoparticles is not particularly restricted, and can be selected from a range from a normal pressure condition to a subcritical or supercritical condition. The temperature under normal atmospheric pressure is preferably from −30° C. to 100° C., more preferably from −10° C. to 60° C., and particularly preferably from 0° C. to 3° C.
The method of mixing an organic pigment solution and a poor solvent is not particularly limited. At the time of mixing the organic pigment solution and the poor solvent, it is preferable that either of them is added to the other in a state of being stirred. It is particularly preferred that mixing is conducted by adding the organic pigment solution to the poor solvent in a state of being stirred. A pump or the like may be or may not be used for adding. As the adding method, a method of adding a liquid inside the other liquid or a method of adding a liquid outside the other liquid may be used; a method of adding a liquid inside the other liquid is preferable. In the method of adding a liquid inside the other liquid, the addition may be carried out via one inlet, or two or more inlets may be used for the addition. The diameter of the inlet for the addition is preferably 20 mm or less, and more preferably 10 mm or less.
The stirring rate for stirring one of the above-described two liquids is preferably 100 to 10,000 rpm, more preferably 150 to 8,000 rpm, and particularly preferably 200 to 6,000 rpm.
The mixing ratio of the organic pigment solution and the poor solvent (a ratio of good solvent/poor solvent) is preferably in a range of from 1/50 to 2/3, more preferably from 1/40 to 1/2, and especially preferably from 1/20 to 3/8, in terms of volume ratio.
The organic nanoparticle concentration in the dispersion liquid containing produced organic nanoparticles is not particularly limited, as long as organic nanoparticles can be dispersed, but the amount of the organic nanoparticles is preferably 10 to 40,000 mg, more preferably 20 to 30,000 mg, and particularly preferably 50 to 25,000 mg, per 1,000 ml of the dispersion solvent.
As to the particle diameter of particles, an average scale of a group can be digitalized by several measurement methods. There are frequently-used parameters such as mode diameter indicating the maximum value of distribution, median diameter corresponding to the median value in the integral frequency distribution curve, and various average diameters (e.g. number-averaged diameter, length-averaged diameter, area-averaged diameter, weight-averaged diameter, volume-averaged diameter), and the like. In the present specification, the particle diameter means a number-averaged diameter, unless otherwise particularly specified. The particle diameter of the pigment fine particles (primary particles) produced by the producing method of the present invention is preferably 1 μm or less (in a state of, e.g., crystal or aggregate of such a size), more preferably 1 to 200 nm, further preferably 2 to 100 nm, and particularly preferably 5 to 80 nm.
Further, in the present invention, a ratio (Mv/Mn) of volume-averaged diameter (Mv) to number-averaged diameter (Mn) is used as the indicator of the monodispersity of particles, unless otherwise particularly specified. The monodispersity, the ratio Mv/Mn, of the pigment fine particles (primary particles) produced by the producing method of the present invention is preferably 1.0 to 2.0, more preferably 1.0 to 1.8, and particularly preferably 1.0 to 1.5.
In the method of producing pigment dispersion composition according to the present invention, favorable embodiments of the production apparatus for use in production of the organic nanoparticles will be explained below, but it should not be construed that these embodiments restrict the technological scope of the present invention.
The stirring blade 12 provided in the above mixing chamber 13 must generate desired mixing strength in the mixing chamber. The mixing strength is presumed to be an important operation factor to the size of a droplet upon mixing of the solution of the organic pigment.
Further it is preferable to properly select the stirring blade 12 having an ability to draw out the organic pigment particles to be formed in a mixing space quickly/immediately to discharge the organic pigment particles to the outside of the mixing chamber 13 quickly/immediately, in order that giant particles may be prevented from being formed, specifically, the formed organic pigment particles may be prevented from remaining in the mixing chamber 13 to: be bonded to other organic pigment particles to become larger particles; or be exposed to the solution of the organic pigment fed into the mixing chamber 13 to become larger particles.
The stirring blade 12 may be of any type, as long as it can attain the aforementioned effects, and, for example, any of a turbine type and a fan turbine type can be used.
Further, as described above, the casing 17 is preferably constituted of a square tube. Thus, a flow produced by the stirring blade 12 is disturbed by a corner of the casing 17, whereby a mixing effect can be further enhanced, without the need for an additional member such as a baffle plate.
The stirring vessel 38 is constituted of: a cylindrical vessel main body 39 with its central axis directed in a vertical direction; and scaling plates 40 as vessel walls for capping the upper and lower opening ends of the vessel main body 39. Further, each of the stirring vessel 38 and the vessel main body 39 is formed of a non magnetic material excellent in magnetic permeability. The two liquid feed ports 32 and 33 are provided at positions close to the lower end of the vessel main body 39, and the liquid discharge port 36 is provided at a position close to the upper end of the vessel main body 39.
Further, the pair of stirring blades 41 and 42 is placed at upper and lower opposing ends in the stirring vessel 38 to be distant from each other, and are rotated in directions opposite to each other. The respective stirring blade 41 and 42 constitutes a magnetic coupling C together with an external magnet 46 placed on the outside of the vessel wall (sealing plate 40) close to the respective stirring blade 41 and 42. That is, the respective stirring blade 41 and 42 is coupled with the corresponding external magnet 46 by a magnetic force, and the blades are rotated in directions opposite to each other, by rotating the respective external magnets 46 with independent motors 48 and 49.
As indicated by a broken line arrow (X) and a solid line arrow (Y) in
Further, the respective stirring blades 41 and 42 in the stirring vessel 38 are coupled with the motors 48 and 49 placed outside the stirring vessel 38 by the magnetic couplings C. As a result, there is no need for inserting a rotation axis into each vessel wall of the stirring vessel 38, so the stirring vessel 38 can take a closed container structure free of a portion (a cavity) through which a rotation axis is inserted. Thus, it is possible to prevent leakage of a stirred and mixed liquid to the outside of the vessel from being occurred, and, at the same time, it is possible to prevent deterioration in processing quality due to contamination, for example, of a lubricating liquid for a rotation axis (a sealing liquid) as an impurity contaminated into the liquid in the vessel 38 from being occurred.
In the present invention, when a pigment dispersion composition is produced, it is possible to produce organic pigment particles according to not only a batch mode but also a continuous flow mode, and also in an industrial scale, by using one of the production apparatuses of such configurations. It is also possible to make the ratio of the organic material solution to the poor solvent solution, supplied to the stirring chamber, consistently constant, by rapidly discharging the organic pigment particle dispersion formed. Thus, the solubility of the organic material in the dispersion liquid can be kept constant during a time commencing on the initiation of the production of the organic pigment particles and ending on the completion of the production, so monodisperse organic pigment particles can be stably produced.
It is further possible to produce monodisperse organic pigment particles more reliably, by preventing discharge of the organic pigment particle dispersion insufficiently stirred and mixed because the liquid flow in the chamber changed to a steady state, and by preventing contamination of the lubricant fluid (sealing fluid) for the rotating shaft as an impurity to the liquid in the chamber.
A production method by using a blade having shearing force will be described as still another embodiment of the apparatus for use in the method of producing pigment dispersion composition according to the present invention.
Herein, the “shearing force” as used in the present specification refers to a shear force (shear stress) to be exerted by a stirring blade on a droplet produced after the mixing of the solution of the organic pigment into the poor solvent.
The shape of the stirring unit that can be used in the present invention is not particularly limited, as long as it is a shape capable of applying high shearing force. General examples of the stirring unit include a paddle blade, a turbine blade, a screw blade, and a Pfaudler blade, and preferable examples of the stirring unit include a dissolver blade and a stirring, emulsifying, and dispersing apparatus having a stirring zone constituted of a revolving turbine unit and a fixed stator unit placed around the turbine unit with a small clearance.
The dissolver blade is a special stirring blade giving high shearing force.
An apparatus as shown in
The stirring speed at which the effects of the present invention can be obtained may vary according to the viscosity and temperature of the poor solvent and the kind and amount of the surfactant to be used, but is preferably from 100 to 10,000 rpm, more preferably from 150 to 8,000 rpm, and particularly preferably from 200 to 6,000 rpm. At a rotational speed below the range, the effects of the present invention could be insufficiently produced. At a rotational speed above the range, air bubbles could be undesirably incorporated into the poor solvent.
In the method of producing pigment dispersion composition of the present invention, the organic nanoparticle dispersion may be subjected to desalting and condensation, whereby an organic nanoparticle dispersion suitable for a color filter coating liquid or for inkjet ink can be produced on an industrial scale.
Hereinafter, the method for concentration of the dispersion is explained below.
The condensation method is not particularly restricted as long as the organic nanoparticle liquid can be concentrated by the method. Examples of a preferable condensation method include: a method involving adding and mixing an extraction solvent to and with an organic nanoparticle dispersion, condensing and extracting the organic nanoparticles to the extraction solvent phase, and filtering the concentrated extract liquid through a filter or the like, to provide a concentrated nanoparticles liquid; a method involving sedimenting the organic nanoparticles by centrifugal separation for condensation; a method involving performing desalting and condensation by ultrafiltration; a method involving sublimating a solvent by vacuum freeze-drying for condensation; and a method involving drying a solvent under heat or reduced pressure for condensation. Alternatively, a combination of two or more of these methods is extremely preferably employed.
The concentration of the organic nanoparticles after concentration is preferably 1 to 100 mass %, more preferably 5 to 100 mass %, and particularly preferably 10 to 100 mass %.
Hereinafter, the method for concentration and extraction is explained below. The extraction solvent that can be used in the concentration extraction is not particularly limited; and a preferable extraction solvent is one which is substantially incompatible (immiscible) with the dispersion solvent (e.g. an aqueous solvent) of the organic nanoparticle dispersion liquid, and which forms an interface when the solvent is left standing after the mixing. (The “substantially incompatible (immiscible) with” as used in the present specification refers to a state where compatibility between the solvents is low, and the amount of the extraction solvent to be dissolved in the dispersion solvent is preferably 50 mass % or less, and more preferably 30 mass % or less.) Further, the extraction solvent is preferably a solvent that causes weak aggregation to such a degree that the organic nanoparticles can be redispersed in the extraction solvent. Herein, “weak, redispersible aggregation” means that aggregates can be redispersed without applying high shearing force such as by milling or high-speed agitation. Such a state is preferable, because it is possible to prevent strong aggregation that may change the particle size and to swell the desired organic nanoparticles with the extraction solvent, besides the dispersion solvent such as water can be easily removed by filter filtration. As the extraction solvents, any of ester-series solvents, alcohol-series solvents, aromatic solvents, and aliphatic solvents are preferable; ester-series solvents, aromatic solvents, and aliphatic solvents are more preferable; ester-series solvents are particularly preferable.
Examples of the ester-series solvents include 2-(1-methoxy)propyl acetate, ethyl acetate, and ethyl lactate. Examples of the alcohol-series solvents include n-butanol and isobutanol. Examples of the aromatic solvents include benzene, toluene and xylene. Examples of the aliphatic solvents include n-hexane and cyclohexane. Furthermore, the extraction solvent may be a pure solvent of one of the preferable solvents above, or alternatively it may be a mixed solvent composed of plurality of the solvents.
An amount of the extraction solvent is not particularly limited, as long as the solvent can extract the organic nanoparticles, but the amount of the extraction solvent is preferably smaller than an amount of the organic nanoparticle dispersion liquid, taking extraction for concentration into consideration. When expressed by volume ratio, the amount of the extraction solvent to be added is preferably in the range of 1 to 100, more preferably in the range of 10 to 90, and particularly preferably in the range of 20 to 80, with respect to 100 of the organic nanoparticle dispersion liquid. A too-large amount may results in prolongation of the time for concentration, while a too-small amount may cause insufficient extraction and residual nanoparticles in the dispersion solvent.
After addition of the extraction solvent, the resultant mixture is preferably stirred and mixed well for sufficient mutual contact with the dispersion liquid. Any usual method may be used for stirring and mixing. The temperature at the time of addition and mixing of the extraction solvent is not particularly limited, but it is preferably 1 to 100° C. and more preferably 5 to 60° C. Any apparatus may be used for addition and mixing of the extraction solvent as long as it can favorably carry out each step. For example, a separatory funnel-like apparatus may be used.
As the method for ultrafiltration, for example, methods used for desalting and concentrating silver halide emulsion can be used. Examples are those methods described in Research Disclosure, No. 10208 (1972), No. 13 122 (1975), No. 16 351 (1977) etc. While pressure difference and flow rate, which are important as the operational conditions, can be selected by referring to the characteristic curves mentioned in Haruhiko Oya, “Maku Riyo Gijutsu Handbook (Membrane Utilization Technique Handbook)”, published by Saiwal Shobo (1978), p. 275, it is necessary to find out optimum conditions for treating a organic nanoparticle dispersion composition of interest in order to suppress aggregation of particles. As a method for supplementing the solvent lost due to passage through the membrane, there are the constant volume method where the solvent is continuously supplemented and the batch method where the solvent is intermittently added. The constant volume method is preferred in the present invention because of its relatively shorter desalting treatment time. As the solvent to be supplemented as described above, pure water obtained by ion exchange or distillation is generally used. A dispersing agent or a poor solvent for dispersing agent may be mixed in the pure water. Alternatively, the dispersing agent or the poor solvent for dispersing agent can also be directly added to the organic nanoparticle dispersion.
As an ultrafiltration membrane, modules of plate type, spiral type, cylinder type, hollow yarn type, hollow fiber type and so forth, in which a membrane is already incorporated, are commercially available from Asahi Chemical Industry Co., Ltd., Daicel Chemical Industries, Ltd., Toray Industries, Inc., NITTO DENKO CORP. and so forth. In view of the total membrane area and washability, those of hollow yarn type and spiral type are preferred. The fractional molecular weight, which is an index of a threshold for substances that can permeate a membrane, must be determined based on the molecular weight of the used dispersing agent. In the present invention, those having a fractional molecular weight of 5,000 to 50,000, more preferably 5,000 to 15,000, are preferably used.
To separate a concentrated extract liquid from a dispersion solvent of the organic nanoparticle dispersion, filtration by using a filter is preferably carried out. As an apparatus for filter filtration, use can be made, for example of a high-pressure filtration apparatus. Preferable examples of the filter to be used include nanofilter, ultrafilter, and the like. It is preferable to remove a residual dispersion solvent by filter filtration, to further concentrate organic nanoparticles in the thus-concentrated extract liquid and to obtain a concentrated nanoparticle liquid.
A method for freeze-drying is not particularly limited, and any method may be adopted as long as a person skilled in the art can utilize the method. Examples of the freeze-drying method include a coolant direct expansion method, a multiple freezing method, a heating medium circulation method, a triple heat exchange method, and an indirect heating freezing method. Of these, the coolant direct-expansion method or the indirect heating freezing method is preferably employed, and the indirect heating freezing method is more preferably employed. In each method, preliminary freezing is preferably performed before freeze-drying is performed. Conditions for the preliminary freezing are not particularly limited, but a sample to be subjected to freeze-drying must be uniformly frozen.
Examples of a device for the indirect heating freezing method include a small freeze-drying machine, an FTS freeze-drying machine, an LYOVAC freeze-drying machine, an experimental freeze-drying machine, a research freeze-drying machine, a triple heat exchange vacuum freeze-drying machine, a monocooling-type freeze-drying machine, and an HULL freeze-drying machine. Of these, the small freeze-drying machine, the experimental freeze-drying machine, the research freeze-drying machine, or the monocooling-type freeze-drying machine is preferably used, and the small freeze-drying machine or the monocooling-type freeze-drying machine is more preferably used.
The temperature for freeze-drying, which is not particularly limited, is, for example, about −190 to −4° C., preferably about −120 to −20° C., and more preferably about −80 to −60° C. The pressure for freeze-drying is not particularly limited either, and can be appropriately selected by a person skilled in the art. It is recommended that freeze-drying be performed under a pressure of, for example, about 0.1 to 35 Pa, preferably about 1 to 15 Pa, and more preferably about 5 to 10 Pa. The time for freeze-drying is, for example, about 2 to 48 hours, preferably about 6 to 36 hours, or more preferably about 16 to 26 hours. It should be noted, however, that these conditions can be appropriately selected by a person skilled in the art. With regard to a method for freeze-drying, reference can be made to, for example, Pharmaceutical machinery and engineering handbook by JAPAN SOCIETY OF PHARMACEUTICAL MACHINERY AND ENGINEERING, Chijinshokan Co., Ltd., p. 120-129 (September, 2000), Vacuum handbook by ULVAC, Inc., Ohmsha, Ltd., p. 328-331 (1992), or Freezing and drying workshop paper by Koji Ito et al., No. 15, p. 82 (1965).
The centrifugal separation method will be explained. A centrifugal separator to be used in the concentration of the organic nanoparticles by centrifugal separation may be any device as long as the device can sediment organic nanoparticles in an organic nanoparticle dispersion liquid (or in an organic nanoparticle concentrated extract liquid). Examples of the centrifugal separator include a widely used device, a system having a skimming function (function with which a supernatant layer is sucked during the rotation of the system, to discharge to the outside of the system), and a continuous centrifugal separator for continuously discharging solid matter.
As the conditions for centrifugal separation, the centrifugal force (a value representing a ratio of an applied centrifugal acceleration to the gravitational acceleration) is preferably 50 to 10,000, more preferably 100 to 8,000, and particularly preferably 150 to 6,000. The temperature at the time of centrifugal separation is preferably −10 to 80° C., more preferably −5 to 70° C., and particularly preferably 0 to 60° C., though a preferable temperature varies depending on the kind of the solvent of the dispersion liquid.
The drying method will be described. For a device for use in the concentration of the organic nanoparticles by drying under reduced pressure, there is no particular limitation as long as the solvent of the organic nanoparticle dispersion liquid (or the organic nanoparticle concentrated extract) can be evaporated. Examples of the device include a widely used vacuum drier and rotary pump, a device capable of drying a liquid under heat and reduced pressure while stirring the liquid, and a device capable of continuously drying a liquid by passing the liquid through a tube the inside of which is heated and reduced in pressure.
The temperature for drying under heat and reduced pressure is preferably 30 to 230° C., more preferably 35 to 200° C., and particularly preferably 40 to 180° C. The pressure for the above-mentioned reduced pressure is preferably 100 to 100,000 Pa, more preferably 300 to 90,000 Pa, and particularly preferably 500 to 80,000 Pa.
In the method of producing the pigment dispersion composition of the present invention, according to the concentration method as described above, it is possible to efficiently concentrate the organic nanoparticles from organic nanoparticle dispersion liquid. With regard to the concentration ratio, for example, when the density of nanoparticles in the organic nanoparticle dispersion liquid as a raw material is defined as 1, the density in the concentrated organic nanoparticle paste can be concentrated to a magnification of preferably about 100 to 3,000, or more preferably about 500 to 2,000.
In the present invention, it is preferable that the concentrated organic nanoparticles are subjected to fining and dispersing treatment again in an organic solvent containing a binder at the time of the production of the pigment dispersion composition. (In the present specification, the term “fining and dispersing” means a process to release particles in a dispersion from the aggregation state, thereby to enhance degree of dispersion.)
In the case of using for color filter, the particles can be added to a vehicle, to be dispersed. If paint is taken as an example, the vehicle means a portion of a medium in which a pigment is dispersed when the paint is in a liquid state. The vehicle is a liquid state and contains a portion (binder) that is to be bonded to the pigment to solidify a coating film and a component (organic solvent) for dissolving and diluting the portion. In the present invention, a binder to be used at the time of the formation of the nanoparticles and a binder to be used in redispersing may be identical to or different from each other, and they are sometimes separately referred to as a nanoparticle formation binder and a redispersion binder, respectively.
The concentration of pigment in a dispersion composition of the pigment after re-dispersion can be properly determined in accordance with a purpose of their use. However, the concentration of the pigment is preferably in the range of from 2 to 30 mass %, more preferably in the range of from 4 to 20 mass %, and especially preferably in the range of from 5 to 15 mass %, based on the total amount of the dispersion composition. In the case where the pigment is dispersed with such vehicles as described above, amounts of the binder and the dissolution and dilution component can be properly determined depending on, for example, the kind of the pigment. However, the amount of the binder is preferably from 1 to 30 mass %, more preferably from 3 to 20 mass %, and especially preferably from 5 to 15 mass %, based on the total amount of the pigment dispersion composition. The amount of the dissolution and dilution component is preferably from 5 to 80 mass %, and more preferably from 10 to 70 mass %, based on the total amount of the pigment dispersion composition.
In the liquid of the concentrated extract nanoparticles described above, in the case of state in which quick filtration through a filter is allowed, organic nanoparticles ordinary aggregate by concentration. In addition, organic nanoparticles concentrated by centrifugal separation or drying also aggregate by concentration.
Examples of a method that can be employed for dispersing such aggregated nanoparticles, include a dispersing method with using a supersonic wave and a method involving applying physical energy. (In the present specification, the term “aggregated nanoparticles” means an assembly of nanoparticles gathered together by a secondary force, such as aggregates.)
Apparatus for ultrasonic wave irradiation to be used is preferably an apparatus that is capable of applying an ultrasonic wave at 10 kHz or more, and examples thereof include an ultrasonic wave homogenizer, an ultrasonic wave cleaning machine, and the like. The liquid temperature during ultrasonic wave irradiation is preferably kept at 1 to 100° C., more preferably 5 to 60° C., since increase in the liquid temperature leads to thermal aggregation of nanoparticles (see Pigment dispersion technique-surface treatment and how to use dispersing agent, and evaluation for dispersibility-, TECHNICAL INFORMATION INSTITUTE CO., LTD, 1999). The temperature can be controlled, for example, by adjusting the temperature of dispersion, by adjusting the temperature of a temperature-controlling layer for controlling of dispersion temperature, or the like.
A dispersion machine to be used at the time of dispersing the concentrated organic nanoparticles by the application of physical energy is not particularly limited, and examples of the dispersion machine include a kneader, a roll mill, an attritor, a super mill, a dissolver, a homomixer, and a sand mill.
The compounds shown as the dispersants used in formation of the organic nanoparticles in the section of [Dispersing agent used at the time of the formation of organic nanoparticles] can also be used favorably for redispersion.
In the pigment dispersion composition according to the present invention, it is possible to make the organic nanoparticles after re-dispersion (primary particles) into finely-dispersed particles and adjust their sizes to a range of preferably 1 to 200 nm, more preferably 2 to 100 nm, particularly preferably 5 to 50 nm. The Mv/Mn of particles after re-dispersion is preferably from 1.0 to 2.0, more preferably from 1.0 to 1.8, and particularly preferably from 1.0 to 1.5.
The pigment particles contained in the pigment-dispersion composition or the pigment dispersion photoresist of the present invention are concentrated and redispersed at a target particle size, irrespective of their minute particle diameters as small as the order of nanometer (for example, 10 to 100 nm). Therefore, the color filter, in which the pigment dispersion composition or the pigment dispersion photoresist is used, can have high optical density, excellent uniformity at the filter surface, and high contrast, and allows noise reduction of images.
Further, the organic pigment particles in the pigment-dispersion composition or the pigment dispersion photoresist of the present invention are dispersed into a state of being uniformly fined to a high degree. Accordingly, the pigment dispersion composition or the pigment dispersion photoresist can deliver a high coloring density even with a thin film thickness and can ensure, for example, reduction in color-filer thickness.
By incorporating pigment having a clear color tone and a high coloring power as the pigment in the pigment-dispersion composition or the pigment dispersion photoresist, the resulting composition or photoresist can be used to advantage as an image forming material for production of color proof, color filter or the like.
Furthermore, since an alkali developer is used in an exposure-development process for formation of colored images, a binder soluble in an alkaline aqueous solution can be used in the pigment-dispersion composition or the pigment dispersion photoresist according to the present invention, and thereby a requirement for environmental protection can also be satisfied.
In the present invention, it is also possible to use an organic solvent having a suitable drying property as the solvent (a dispersing medium for the pigment) to be used in the pigment-dispersion composition or the pigment dispersion photoresist, so the requirement for the drying after coating can be satisfied too.
The pigment dispersion photoresist in the present invention contains the above phthalocyanine-series pigment fine particles, and preferably contains (1) organic nano-particles formed as particles having a particle diameter of 1 μm or less from an organic pigment by mixing a solution obtained by dissolving the organic pigment in a good solvent, in the presence of a binder (A), with a poor solvent compatible with the good solvent, (2) a binder (B), (3) a monomer or oligomer, and (4) a photopolymerization initiator or photopolymerization initiator series. Herein, the binders (A) and (B) may be the same or different.
The ingredients (a) to (d) and so on in the pigment dispersion photoresist of the present invention are explained below.
The method of producing the organic nanoparticles has been described in detail. The content of the organic nanoparticles is preferably from 3 to 60% by mass, and further preferably from 5 to 40% by mass, based on the total solids of the pigment dispersion photoresist (as used herein, the term “total solids” refers to the total amount of all the components of the composition, exclusive of the organic solvent(s)). When the content is too high, there sometimes occurs an increase in viscosity of the resultant dispersion liquid and leading to a problem in production suitability. When the content is too low, on the other hand, sufficient coloring power cannot be obtained. In order to perform a function as a coloring agent, it is preferred that the organic nanoparticles (pigment particles) have a particle diameter of preferably 0.1 μm or less, especially preferably 0.08 μm or less.
The redispersing binder used for redispersion is not particularly limited, as long as the binder is an acidic group-containing binder, and those described above in the [Binder] section are preferably used as redispersing binders. The redispersing binder is preferably a compound having a similar structure to that of the nanoparticle-forming alkali-soluble binder that is added when the organic pigment particles are formed. Most preferably, both binders are the same. The content of the redispersing binder (which may be the sum total of the content of the redispersing binder and the residual content of the nanoparticle formation alkali-soluble binder when the latter binder remains) is generally from 15 to 50 mass %, preferably from 20 to 45 mass %, based on the total solids in the pigment dispersion photoresist. If the amount of the binder is too large, viscosity of the composition becomes too high, which causes problem in production suitability. On the other hand, if the amount of the binder is too small, problems in coating film formation arise.
The monomer or oligomer contained in the pigment dispersion photoresist of the present invention is preferably a monomer or oligomer which has two or more ethylenically unsaturated double bonds and which undergoes addition-polymerization by irradiation with light. The monomer or oligomer may be a compound having at least one addition-polymerizable ethylenically unsaturated group therein and having a boiling point of 100° C. or higher at normal pressure. Examples thereof include: a monofunctional acrylate and a monofunctional methacrylate such as polyethylene glycol mono(meth)acrylate, polypropylene glycol mono(meth)acrylate, and phenoxyethyl(meth)acrylate; polyethylene glycol di(meth)acrylate, polypropylene glycol di(meth)acrylate, trimethylolethane triacrylate, trimethylolpropane tri(meth)acrylate, trimethylolpropane diacrylate, neopentyl glycol dimethacrylate, pentaerythritol tetra(meth)acrylate, pentaerythritol tri(meth)acrylate, dipentaerythritol hexa(meth)acrylate, dipentaerythritol penta(meth)acrylate, hexanediol di(meth)acrylate, trimethylolpropane tri(acryloyloxypropyl)ether, tri(acryloyloxyethyl)isocyanurate, tri(acryloyloxyethyl)cyanurate, glycerin tri(meth)acrylate; a polyfunctional acrylate or polyfunctional methacrylate which may be obtained by adding ethylene oxide or propylene oxide to a polyfunctional alcohol such as trimethylolpropane or glycerin and converting the adduct into a (meth)acrylate.
Examples of the monomer and oligomer further include urethane acrylates as described in JP-B-48-41708, JP-B-50-6034, and JP-A-51-37193; and polyester acrylates as described in JP-A 48-64183, JP-B-49-43191, and JP-B=52=30490; polyfunctional acrylates or polyfunctional methacrylates such as epoxy acrylates which are reaction products of an epoxy resin and (meth)acrylic acid.
Among these, trimethylolpropane tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and dipentaerythritol penta(meth)acrylate are preferable.
Further, other than the above, “polymerizable compound B” described in JP-A-11-133600 can be mentioned as a preferable example.
These monomers or oligomers have a molecular weight of 200 to 1000, and they may be used singly or as a mixture of two or more kinds thereof. The content of the monomer or oligomer is generally in a range of from 5 mass % to 50 mass %, preferably from 10 mass % to 40 mass %, based on the total solid content of the pigment dispersion photoresist. If this content is too large, viscosity of the composition becomes too high, which causes problem in production suitability. If the content is too small, a curing force at the time of exposure becomes insufficient.
Examples of the photopolymerization initiator or the photopolymerization initiator series (in the present specification, the term “photo-polymerization initiator series” means a polymerization initiating mixture that exhibits a function of photo-polymerization initiation with a plurality of compounds combined with each other or a polymerization initiating composition of compounds having the ability to initiate photopolymerization) that can be contained in the pigment dispersion photoresist of the present invention include vicinal polyketaldonyl compounds disclosed in U.S. Pat. No. 2,367,660, acyloin ether compounds described in U.S. Pat. No. 2,448,828, aromatic acyloin compounds substituted by an α-hydrocarbon described in U.S. Pat. No. 2,722,512, polynuclear quinone compounds described in U.S. Pat. No. 3,046,127 and U.S. Pat. No. 2,951,758, combinations of triarylimidazole dimer and p-aminoketone described in U.S. Pat. No. 3,549,367, benzothiazole compounds and trihalomethyl-s-triazine compounds described in JP-B-51-48516, trihalomethyl-triazine compounds described in U.S. Pat. No. 4,239,850, and trihalomethyloxadiazole compounds described in U.S. Pat. No. 4,212,976. In particular, trihalomethyl-s-triazine, trihalomethyloxadiazole, and triarylimidazole dimer are preferable.
In addition, “polymerization initiator C” described in JP-A-11-133600 can also be mentioned as preferable examples.
These photopolymerization initiators and photopolymerization initiator series each may be used singly. Alternatively, a mixture of two or more selected from these photopolymerizable initiators and photopolymerization initiator series may be used. In particular, it is preferable to use two or more kinds of photopolymerizable initiators and photopolymerization initiator series. When two or more kinds of photopolymerizable initiators and photopolymerization initiator series are used, the display property, particularly evenness of display, can be improved.
As to the content of the photo-polymerization initiator and the photo-polymerization initiator series, the content thereof is generally from 0.5 to 20 mass %, preferably from 1 to 15 mass %, based on the total solid content of the pigment dispersion photoresist. If the amount of the initiator or the initiator series is too large, exposure sensitivity becomes too high, which causes difficulty in control. If the amount of the initiator or the initiator series is too small, exposure sensitivity becomes too low.
Besides the above components, an organic solvent may be further used in the pigment dispersion photoresist according to the present invention. Examples of the organic solvent may include methyl ethyl ketone, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, cyclohexanone, cyclohexanol, methyl isobutyl ketone, ethyl lactate, methyl lactate and caprolactam. The content of the solvent is preferably 10 to 95% by mass based on the total amount of the photoresist.
Conventionally used color filters had a problem that the color of each pixel was deep in order to realize a high color purity, whereby unevenness of the film thickness of pixels was directly recognized as color unevenness. For this reason, it has been desired to suppress the film thickness change, which directly influences the film thickness of pixels, during the process of forming (applying) the photosensitive resin layer.
In the color filter of the present invention or the photosensitive resin transfer material of the present invention, the pigment dispersion photoresist preferably comprises a suitable surfactant from the viewpoint of achieving a uniform film thickness and of prevention of uneven coating (color unevenness caused by change in the film thickness) effectively.
Preferable examples of the surfactant include surfactants disclosed in JP-A-2003-337424 and JP-A-11-133600. The content of the surfactant is preferably 5 mass % or less based on the total content of the photoresist.
It is preferred that the pigment dispersion photoresist of the present invention includes a thermal polymerization inhibitor. Examples of the thermal polymerization inhibitor include hydroquinone, hydroquinone monomethyl ether, p-methoxyphenol, di-t-butyl-p-cresol, pyrogallol, t-butylcatechol, benzoquinone, 4,4′-thiobis(3-methyl-6-t-butylphenol), 2,2′-methylenebis(4-methyl-6-t-butylphenol), 2-mercaptobenzimidazole, and phenothiazine. The content of the thermal polymerization inhibitor is preferably 1 mass % or less based on the total amount of the photoresist.
—Dye and Pigment to be used Supplementarily—
In addition to the above coloring agent (pigment), other coloring agents (dyes or pigments) may be added, according to the need, in the pigment dispersion photoresist according to the present invention, to the extent that the effects of the present invention are not impaired. When the coloring agent is a pigment, the pigment is preferably dispersed in the pigment dispersion photoresist uniformly; therefore, the particle diameter of such a pigment is preferably 0.1 μm or smaller, more preferably 0.08 μM or smaller.
Examples of the dye and pigment include the colorants disclosed in paragraph Nos. [0038] to [0040] of JP-A-2005-17716, pigments disclosed in paragraph Nos. to [0072] of JP-A-2005-361447, and coloring agents disclosed in paragraph Nos. to [0088] of JP-A-2005-17521. The content of dyes or pigments to be used supplementary is preferably 5 mass % or less based on the total content of the photoresist
If necessary, the pigment dispersion photoresist of the present invention may include an ultraviolet absorber. Examples of the ultraviolet absorber include compounds disclosed in JP-A-5-72724, a salicylate-based ultraviolet absorber, a benzophenone-based ultraviolet absorber, a benzotriazole-based ultraviolet absorber, a cyanoacrylate-based ultraviolet absorber, a nickel-chelate-based ultraviolet absorber, and a hindered-amine-based ultraviolet absorber.
Specific examples thereof include phenyl salicylate, 4-t-butyl phenylsalicylate, 2,4-di-t-butyl phenyl-3′,5′-di-t-4′-hydroxybenzoate, 4-t-butyl phenylsalicylate, 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-n-octoxybenzophenone, 2-(2′-hydroxy-5′-methylphenyl)benzotriazole, 2-(2′-hydroxy-3′-t-butyl-5′-methylphenyl)-5-chlorobenzotriazole, ethyl-2-cyano-3,3-diphenyl acrylate, 2,2′-hydroxy-4-methoxybenzophenone, nickel dibutyl dithiocarbamate, bis(2,2,6,6-tetramethyl-4-pyridine)-sebacate, 4-t-butyl phenylsalicylate, phenyl salicylate, 4-hydroxy-2,2,6,6-tetramethylpiperidine condensate, succinic acid-bis(2,2,6,6-tetramethyl-4-piperidenyl)-ester, 2-[2-hydroxy-3,5-bis(α,α-dimethylbenzyl)phenyl]-2H-benzotriazole, and 7-{[4-chloro-6-(diethylamino)-5-triazine-2-yl]amino}-3-phenylcoumarin. The content of the ultraviolet absorber is preferably 5 mass % or less based on the total amount of the photoresist.
In addition to the aforementioned additives, the pigment dispersion photoresist of the present invention may further include an “adhesion auxiliary” described in JP-A No. 11-133600 and other additives.
The coating film of the pigment dispersion photoresist in the present invention contains (1) organic nano-particles formed as particles having a particle diameter of 1 μm or less from an organic pigment by mixing a solution obtained by dissolving the organic pigment in a good solvent in the presence of an alkali-soluble binder (A) having an acid group, with a poor solvent compatible with the good solvent, (2) an alkali-soluble binder (B) having an acid group, (3) a monomer or oligomer, and (4) a photopolymerization initiator or photopolymerization initiator series.
The above essential components (1) to (4) and other components in the coating film of the pigment dispersion photoresist according to the present invention are the same as those already described in the above paragraph <Pigment dispersion photoresist>. The thickness of the coating film of the pigment dispersion photoresist of the present invention may be properly determined. However, the thickness is preferably in the range of from 0.5 μm to 5.0 μm, and more preferably from 1.0 μm to 3.0 μm.
The aforementioned coating film can be formed by coating the pigment dispersion photoresist of the present invention by a general coating method, followed by drying. In the present invention, it is preferred that the pigment dispersion photoresist be coated by using a slit nozzle having a slit at a portion through which the coating liquid is discharged. Specifically, slit nozzles and slit coaters described in JP-A-2004-89851, JP-A-2004-17043, JP-A-2003-170098, JP-A-2003-164787, JP-A-2003-10767, JP-A-2002-79163, and JP-A-2001-310147 are preferably used.
Next, the colored transfer material of the present invention will be explained.
The colored transfer material of the present invention is preferably formed by using the photosensitive resin transfer material as described in JP-A-5-72724, that is a composite film. The structure of the composite film may be, for example, a lamination in which a temporary support, a thermoplastic resin layer, an intermediate layer, a photosensitive resin layer, and a protective film are disposed in this order. The colored transfer material according to the present invention is a material having a photosensitive resin layer provided by using the above-described pigment dispersion photoresist of the present invention.
In the colored transfer material of the present invention, it is preferable that the temporary support has flexibility and does not remarkably deform, shrink, or elongate even under pressure or under pressure and heat. Examples of such a temporary support include a polyethylene terephthalate film, a cellulose triacetate film, a polystyrene film, and a polycarbonate film. Among them, a biaxially-stretched polyethylene terephthalate film is particularly preferable.
The component used in the thermoplastic resin layer is preferably an organic polymer substance described in JP-A-5-72724. The substance can be preferably selected from organic polymer substances having a softening point of about 80° C. or lower according to the Vicat method (specifically, the method of measuring a polymer softening point according to American Material Test Method ASTMD 1235). Specifically, the substance may be an organic polymer, and examples thereof include: a polyolefin such as polyethylene or polypropylene; an ethylene copolymer such as a copolymer of ethylene and vinyl acetate or a saponified product thereof; a copolymer of ethylene and acrylic acid ester or a saponified product thereof; polyvinyl chloride; a vinyl chloride copolymer such as a copolymer of vinyl chloride and vinyl acetate or a saponified product thereof; polyvinylidene chloride; a vinylidene chloride copolymer; polystyrene; a styrene copolymer such as a copolymer of styrene and (meth)acrylic acid ester or a saponified product thereof; polyvinyl toluene; a vinyltoluene copolymer such as a copolymer of vinyltoluene and (meth)acrylic acid ester or a saponified product thereof; poly(meth)acrylic acid ester; a (meth)acrylic acid ester copolymer such as a copolymer of butyl(meth)acrylate and vinyl acetate; and a polyamide resin such as a vinyl acetate copolymer nylon, a copolymerized nylon, N-alkoxymethylated nylon, and N-dimethylaminated nylon.
In the colored transfer material of in the present invention, it is preferable to provide an intermediate layer so as to prevent mixing of components during application of a plurality of coating layers and during storage after the application. The intermediate layer is preferably an oxygen blocking film having oxygen blocking function described as “a separating layer” in JP-A-5-72724. By using such an oxygen blocking film, the exposure sensitivity is heightened, the time load of the exposing machine is decreased, and the productivity is improved.
The oxygen blocking film is preferably a film with a low oxygen permeability and is dispersible or soluble in water or an aqueous alkaline solution. Such a film may be properly selected from ordinary oxygen blocking films. Among them, a combination of polyvinyl alcohol and polyvinylpyrrolidone is particularly preferable.
It is preferable to provide a thin protective film on a photosensitive resin layer in order to protect the photosensitive resin layer from pollution or damage at storage. The protective film may comprise a material which is the same as or similar to that of the temporary support, but the protective film should be easily separated from the photosensitive resin layer. The protective film material may be, for example, silicone paper, polyolefin sheet or polytetrafluoroethylene sheet.
The colored transfer material of the present invention can be prepared by: coating a temporary support with a coating liquid (coating liquid for thermoplastic resin layer) in which additives for a thermoplastic resin layer are dissolved and drying the coating liquid to form a thermoplastic resin layer; and then coating the thermoplastic resin layer with a coating liquid for intermediate layer containing a solvent which does not dissolve the thermoplastic resin layer, and drying the coating liquid for intermediate layer; and then, coating the intermediate layer with a composition for photosensitive resin layer containing a solvent which does not dissolve the intermediate layer, and drying the composition for photosensitive resin layer, to form a photosensitive resin layer composed of the colored photosensitive resin composition of the present invention.
Alternatively, the colored transfer material may be prepared by: preparing a sheet in which a thermoplastic resin layer and an intermediate layer are disposed on the aforementioned temporary support, and a sheet in which a photosensitive resin layer is disposed on a protective film, and adhering the sheets to each other such that the intermediate layer and the photosensitive resin layer contact each other. The colored transfer material may also be prepared by: preparing a sheet in which a thermoplastic resin layer is disposed on the aforementioned temporary support, and a sheet in which a photosensitive resin layer and an intermediate layer are disposed on a protective film, and adhering the sheets to each other such that the thermoplastic resin layer and the intermediate layer contact each other.
In the colored transfer material of the present invention, the thickness of the photosensitive resin layer is preferably 1.0 to 5.0 μm, more preferably 1.0 to 4.0 μm, and particularly preferably 1.0 to 3.0 μm. The thicknesses of respective layers are not limited to the above ranges. In general, the thickness of the temporary support is preferably 15 to 100 μm, the thickness of the thermoplastic resin layer is preferably 2 to 30 μm, the thickness of the intermediate layer is preferably 0.5 to 3.0 μm, and the thickness of the protective film is preferably 4 to 40 μm.
The coating operation in the production method above may be carried out, for example, with a common coating apparatus. However, in the present invention, it is preferably performed with a coating apparatus (slit coater) having a slit nozzle, as explained in the previous section of <Coating film of the pigment dispersion photoresist>. Preferable examples of the slit coater are as described above.
The color filter of the present invention is excellent in contrast. The term “contrast” used in the present specification means a ratio of the amount of transmitted light when polarization axes are parallel to the amount of transmitted light when polarization axes are perpendicular, with respect to a color filter placed between two polarizing plates (see, for example, The 7th Color Optics Conference 1990; Color Filter for 512-color 10.4″-size TFT-LCD; Ueki, Koseki, Fuktmaga, Yamanaka).
The color filter having a high contrast enables enlarging a discrimination of brightness at the time when the color filter is combined with a liquid crystal. Therefore, the high contrast is a very important performance in enhancing replacement of CRTs by liquid crystal display devices. The contrast of the color filter according to the present invention is, if it is a monochromatic type, preferably 3,000 or more, more preferably 5,000 or more, and especially preferably 7,000 or more. With respect to a color filter having R pixel, G pixel, and B pixel, and, if necessary, further provided with a black matrix, the contrast is preferably 3,000 or more preferably 5,000 or more, and especially preferably 6,000 or more. The present invention is characterized in that such a high contrast can be realized thereby.
In the case where the color filter of the present invention is used as a color filter for a television monitor, the difference (ΔE) between the chromaticity of the red (R) photosensitive resin layer measured under a F10 light source and the target chromaticity for red shown in the following table, the difference (ΔE) between the chromaticity of the green (G) photosensitive resin layer measured under a F10 light source and the target chromaticity for green shown in the following table, the difference (ΔE) between the chromaticity of the blue (B) photosensitive resin layer measured under a F10 light source and the target chromaticity for blue shown in the following table, are each preferably 5 or less, more preferably 3 or less, still more preferably 2 or less.
Herein, chromaticity in the present invention is measured by a microscopic spectrophotometer (OSP100 or 200, manufactured by Olympus Optics) and expressed in terms of xyY values of the xyz color system obtained by calculation as a result under an F10-light source at 2-degree viewing angle. In addition, the difference from the target chromaticity is expressed in terms of a color difference of a La*b* color system.
The color filter of the present invention can be produced by, for example, a method of repeating, until the layers of the respective colors are provided, the process comprising: forming a photosensitive resin layer on a substrate; and exposing and developing the photosensitive resin layer. Black matrix may be introduced so as to partition the boundaries of the photosensitive resin layers, in accordance with the necessity.
In the above production method, formation of the photosensitive resin layer on a substrate may be conducted, for example, by (a) applying the respective pigment dispersion photoresists by an ordinary coating device or by (b) using the aforementioned colored transfer material so as to adhere the photosensitive resin layer by a laminator,
The pigment dispersion photoresist in production of the color filter according to the present invention, may be coated, for example, with a common coating apparatus, but in the present invention, it is preferably performed with a slit coater as described in the previous section of <Coating film of colored photosensitive resin composition>. Preferable examples of the slit coater are as described above. When the photosensitive resin layer is formed by coating, its film thickness is preferably 1.0 to 3.0 μm, more preferably 1.0 to 2.5 μm, and still more preferably 1.0 to 2.0 μm.
Using the above-described colored transfer material of the present invention, the photosensitive resin layer formed into a film shape may be adhered to the substrate explained below by a heated and/or pressurized roller or flat plate by pressure adhesion or heat pressure adhesion. Specifically, laminators and laminating methods described in the following documents may be used: JP-A-7-110575, JP-A-11-77942, JP-A-2000-334836, and JP-A-2002-148794. From the viewpoint of suppression of contamination by foreign substances, it is preferable to use the method described in JP-A-7-110575. The preferred thickness of the film, when forming a photosensitive resin layer with the colored transfer material according to the present invention, is the same as the thickness described in the section of <Colored transfer material>.
In the present invention, the substrate on which a color filter is to be formed may be, for example, a transparent substrate, and examples thereof include known glass plates such as a soda glass plate having a silicon oxide film on its surface, a low-expansion glass, a non-alkali glass, and a quartz glass plate, and a plastic film.
By subjecting the substrate to a coupling treatment in advance, adhesion of the substrate to the pigment dispersion photoresist or the colored transfer material can be improved. The method described in JP-A-2000-39033 is preferable as the coupling treatment. The thickness of the substrate is not particularly limited, and is preferably 700 to 1,200 μm in general.
In the color filter of the present invention, when the photosensitive resin layer is formed by application of the pigment dispersion photoresist, an oxygen blocking film may further be provided on the photosensitive resin layer, whereby the exposure sensitivity can be improved. Examples of the oxygen blocking film include the same ones as already mentioned in the description about the item of (Interlayer) of the <Colored transfer material>. The thickness of the oxygen blocking film is not particularly limited, and the thickness is preferably 0.5 to 3.0 μm in general.
The color filter of the present invention can be obtained by repeating, until the resin layers of the respective colors are provided, the process comprising: arranging a predetermined mask over a photosensitive resin layer formed on a substrate; exposing the photosensitive resin layer to light from above the mask which has passed through the mask, the thermoplastic resin layer, and the intermediate layer, and then developing the photosensitive resin layer with a developer.
The light source for the exposure can be suitably selected from light sources capable of emitting lights within the wavelength region capable of curing the photosensitive resin layer (e.g. 365 nm, 405 nm, etc.). Specific examples thereof include an ultrahigh-pressure mercury lamp, a high-pressure mercury lamp, and a metal halide lamp. The exposure amount is usually about 5 to 200 mJ/cm2, and preferably about 10 to 100 mJ/cm2.
The developer is not particularly limited and may be an ordinary developer such as the developer described in JP-A-5-72724. The developer is preferably a developer of a type which dissolves a photosensitive resin layer; for example, a developer containing a compound with a pKa of 7 to 13 at a concentration of 0.05 to 5 mol/L is preferable. The developer may include a small amount of an organic solvent miscible with water.
Examples of the organic solvent miscible with water include methanol, ethanol, 2-propanol, 1-propanol, butanol, diacetonealcohol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol mono-n-butyl ether, benzyl alcohol, acetone, methyl ethyl ketone, cyclohexanone, ε-caprolactone, γ-butyrolactone, dimethylformamide, dimethylacetamide, hexamethylphosphoramide, ethyl lactate, methyl lactate, ε-caprolactam, and N-methylpyrrolidone. The concentration of the organic solvent is preferably 0.1 mass % to 30 mass %.
An ordinary surfactant may be further added to the developer. The concentration of the surfactant is preferably 0.01 mass % to 10 mass %.
The developing method may be an ordinary method such as paddle development, shower development, shower & spin development, or dip development.
Herein, the shower development will be explained. In the shower development, the developer is sprayed onto the exposed photosensitive resin layer with a shower, so that the uncured portion is removed. It is preferable to spray an alkaline solution having poor ability to dissolve the photosensitive resin layer by using a shower or the like before development, so as to remove the thermoplastic resin layer, the intermediate layer and the like. Further, after development, it is preferable to spray a cleaner or the like by using a shower while rubbing the surface with a brush or the like to remove the development residue.
The liquid temperature of the developer is preferably 20° C. to 40° C., and the pH of the developer is preferably 8 to 13.
In an embodiment of the present invention, at the time of the production of the color filter of the present invention, the pigment dispersion photoresist for forming a color filter are stacked to form a base, a transparent electrode is formed thereon, and protrusions for split-orientation is her provided thereon to form a spacer, as described in JP-A-11-248921 and Japanese Patent No. 3255107. This embodiment is preferable from the viewpoint of cost reduction.
When the pigment dispersion photoresists are stacked by successive coating operations, the film thickness becomes smaller in every overlaying owing to the leveling of the coating liquid. For this reason, it is preferable to stack the four colors of K (black), R, G, and B and to provide protrusions for split-orientation thereon. On the other hand, when the transfer material having a thermoplastic resin layer is used, it is preferable to stack two or three colors since the thicknesses are maintained constant.
In order to prevent deformation of the photosensitive resin layer upon lamination by overlaying the transfer material and to maintain a constant thickness, the size of the base is preferably 25 μm×25 μm or larger, more preferably 30 μm×30 μm or larger.
The liquid crystal display device of the present invention is excellent in definition such as black depth owing to the use of the color filter that is excellent in contrast according to the present invention. The liquid crystal display device of the present invention can be suitably used also as a large screen liquid crystal display device such as a display for a notebook computer and a television monitor.
The nano-size phthalocyanine-series pigment fine particles obtained by the production method of the present invention enable the production of a pigment dispersion composition superior in dispersibility and fluidity. Also, the pigment dispersion photoresist and colored transfer material according to the present invention can exhibit high color density even in a low film thickness. Also, the color filter of the present invention has excellent contrast and light fastness. Also, the liquid crystal display device of the present invention enables a high discrimination of brightness from darkness and is therefore superior in imaging quality such as blackness (black depth).
The present invention will be described in more detail based on examples given below, but the invention is not meant to be limited by these.
3.3 ml of a 28% solution of sodium methoxide in methanol, 6,000 mg of a pigment (Pigment Green 36), 6,000 mg of polyvinyl pyrrolidone, and 600 mg of a pigment-dispersing agent A were added to 100 ml of dimethyl sulfoxide, to prepare a pigment solution A.
Separately, 1,000 ml of water containing 4.3 ml of 1-mol/l hydrochloric acid was prepared as a poor solvent.
The pigment-dispersing agent A was prepared according to the method described in JP-A-2000-239554.
200 ml of the pigment solution A was fed using an NP-KX-500 large-volume nonpulsating pump manufactured by Nihon Seimitsu Kagaku Co., Ltd., at a flow rate of 50 ml/min into 1,000 ml of water as the poor solvent controlled to a temperature of 1° C. and being stirred at 500 rpm by a GK-0222-10 Ramond stirrer manufactured by Fujisawa Pharmaceutical Co., Ltd., thereby forming nano-size pigment particles, to give a pigment dispersion A. Analysis of the particle diameter and the monodispersion degree of the pigment dispersion A by using Nanotrack UPA-EX150 manufactured by Nikkiso showed a number-average diameter of 32 nm and a Mv/Mn ratio of 1.35.
The prepared pigment dispersion liquid A (having a nano-size pigment concentration of about 0.5 mass %) was added with 500 ml of 2-(1-methoxy)propylacetate, and the whole was stirred at 25° C. for 10 minutes at 500 rpm. After that, the resultant was left standing for 1 day, and a nano-size pigment was extracted to a 2-(1-methoxy)propylacetate phase, whereby a concentrated extract liquid was obtained.
The concentrated extract liquid containing the extracted nano-size pigment was filtered by using an EP-010 filter manufactured by SUMITOMO ELECTRIC FINE POLYMER INC., whereby a paste-like concentrated pigment liquid A (having a nano-size pigment concentration of 35 mass %) was obtained.
A pigment dispersion composition A having the following composition was prepared by using the above paste.
The pigment composition having the above composition was dispersed with using zirconia beads of 0.65 mm in diameter, at a peripheral speed of 9 m/s, for 1 hour, using a motor mill M-50 (manufactured by Eigar Japan).
A pigment solution B was prepared and her a pigment dispersion liquid B was prepared both in the same manner as in Example 1, except that the following pigment-dispersing agent B was used in place of the pigment-dispersing agent A used in Example 1. The particle diameter and the degree of monodispersion were measured to find that the number average particle diameter was 34 nm and Mv/Mn was 1.30. Moreover, a concentrated pigment liquid B (the concentration of nano-size pigment: 35% by mass) having a paste form was prepared and further, a pigment dispersion composition B was prepared both in the same manner as in Example 1.
The pigment-dispersing agent B was synthesized according to the method of preparation of the pigment dispersing agent c described in JP-B-5-72943.
A pigment solution C was prepared and further a pigment dispersion liquid C was prepared both in the same manner as in Example 1, except that the following pigment-dispersing agent C represented by formula (IV) was used in place of the pigment-dispersing agent A used in Example 1. The particle diameter and the degree of monodispersion were measured to find that the number average particle diameter was 37 nm and Mv/Mn was 1.30. Moreover, a concentrated pigment liquid C (the concentration of nano-size pigment: 35% by mass) having a paste form was prepared and further, a pigment dispersion composition C was prepared, both in the same manner as in Example 1.
The pigment-dispersing agent C represented by formula (IV) described below was synthesized according to the method of the synthesizing example 1 described in JP-A-2001-31885.
A pigment dispersion liquid D was prepared in the same manner as in Example 1, except that the pigment solution A used in Example 1 was altered to a pigment solution D manufactured in the following method. The particle diameter and the degree of monodispersion were measured to find that the number average particle diameter was 34 nm and Mv/Mn was 1.30. Further, a concentrated pigment liquid D (concentration of a nano-size pigment: 35% by mass) having a paste form was prepared and further, a pigment dispersion composition D was prepared, both in the same manner as in Example 1.
3.3 ml of a 28% solution of sodium methoxide in methanol, 6,000 mg of a pigment (Pigment Blue 15:6), 6,000 mg of polyvinylpyrrolidone, 300 mg of EFKA6745, and 300 mg of Disperon DA-725 were added in 100 ml of dimethylsulfoxide, to prepare a pigment solution D.
A pigment dispersion liquid E was prepared in the same manner as in Example 1, except that the pigment solution A used in Example 1 was altered to a pigment solution E manufactured in the following method. The particle diameter and the degree of monodispersion were measured to find that the number average particle diameter was 32 nm and Mv/Mn was 1.30. Moreover, a concentrated pigment liquid L (concentration of a nano-size pigment: 35% by mass) having a paste form was prepared and further, a pigment dispersion composition E was prepared, both in the same manner as in Example 1.
3.3 ml of a 28% solution of sodium methoxide in methanol, 6,000 mg of a pigment (Pigment Green 7), 6,000 mg of polyvinylpyrrolidone, and 600 mg of the pigment dispersing agent A were added in 100 ml of dimethylsulfoxide, to prepare a pigment solution E.
A pigment dispersion composition F having the composition below was prepared as described below using a bead dispersing machine.
Into a 1-methoxy-2-propylacetate solution, was charged the pigment-dispersing agent A, a pigment (Pigment Green 36) in a powder form, 6 g of polyvinyl pyrrolidone, and a methacrylic acid/benzyl methacrylate copolymer, followed by stirring, to prepare a mixture solution. Then, the mixture solution was subjected to dispersion treatment for 9 hours by using zirconia beads 0.65 mm in diameter and a Motor Mill M-50 (manufactured by Eiger Japan Co., Ltd.) under a condition that the circumferential velocity was set at 9 m/s.
Pigment Green 36 in an amount of 40 parts, pulverized sodium chloride in an amount of 400 parts, and diethylene glycol in an amount of 80 parts were added to a double-arm kneader and kneaded at a temperature of 100° C. to 110° C. for 8 hours. The mixture was then poured into 100 parts of an aqueous 1% hydrochloric acid solution at 80° C. and stirred for 1 hour. Thereafter, the mixture was filtered, washed with hot water, dried, and pulverized, so that a fined pigment of the Pigment Green 36 was obtained. This fined pigment was used in place of the pigment (Pigment Green 36) of the above Comparative Example 1, to obtain a pigment dispersion composition G.
The pigment dispersion compositions A to E were prepared by using the following reagents. In the examples “parts” means “mass parts”, “%” means “mass %” and “molecular weight” means “weight-average molecular weight”, unless otherwise indicated.
The pigment dispersion compositions A to G obtained in Examples 1 to 5 and Comparative Examples 1 and 2 were each applied to a glass substrate in a thickness of 2 μm, to prepare respective samples. A three-wavelength cold-cathode-tube light source (trade name: FWL18EX-N), manufactured by Toshiba Lightee (k.k.), provided with a diffusion plate was used as the backlight unit, to measure the quantities of transmitted light when two polarizing plates (trade name: G1220DUN, manufactured by Nitto Denko Corp.) were disposed such that their polarization axes were parallel or perpendicular to each other. The ratio of the quantity of transmitted light when the polarization axes of the polarizing plates were parallel to each other to the quantity of transmitted light when the polarization axes of the polarizing plates were perpendicular to each other was defined as the contrast (see, for example, Color Filter for 512-color display 10.4″-size TFT-LCD, co-authored by Ucki, Koseki, Fukunaga, and Yamanaka, The seventh Color Optics Conference (1990), etc.).
Chromaticity was measured using a color luminance meter (BM-5 manufactured by Topeon Techno House Corporation). The above-described two sheets of polarizing plates, sample, and color luminance meter were placed at the following positions: A polarizing plate was disposed at the distance of 13 mm from the backlight. A cylinder of 11 mm in diameter and 20 mm in length was disposed at the distance of 40 mm to 60 mm from the backlight. The light transmitted through the cylinder was irradiated to a sample to be measured disposed at the distance of 65 mm from the backlight. The transmitted light was passed through another polarizing plate disposed at the distance of 100 mm from the backlight and measured with a color luminance meter disposed at the distance of 400 mm from the backlight. The measuring angle in the color luminance meter was set to 2°. The light amount of the backlight was set so that its brightness (luminance) would be 1280 cd/m2, when the two sheets of polarizing plates were arranged in a position of parallel nicol and no sample was disposed.
Also, for a test of light fastness, the above samples were irradiated with light from a metal halide lamp at a dose of 90 mW/cm2 for 12 hours, to measure a change ΔEab* in chromaticity before and after the irradiation. The chromaticity in the present invention was determined by using a microspectrophotometer (OSP100 or 200, manufactured by Olympus Optics), and expressed as values xyY in the xyz color system that were calculated as the result obtained at a visual field angle of 2 degrees to a F10 light source. The difference in chromaticity was expressed by the color difference in the La*b* color system. The color difference is desirably smaller.
The results of measurement of the contrast and ΔEab* of the samples obtained from the pigment dispersion compositions A to G are shown in Table 1.
It is understood from Table 1 that the pigment dispersion compositions A to E of Examples 1 to 5 respectively containing fine particles of the phthalocyanine compound pigments produced by the production method of the present invention are far superior in contrast to Comparative Example 1 (pigment dispersion composition F) manufactured by an Eiger mill which is usually used in the field concerned and to Comparative Example 2 (pigment dispersion composition G) in which the pigment is fined by salt milling.
It is also understood that the pigment dispersion compositions A to E are very superior in light fastness to the pigment dispersion compositions F and G.
The pigment dispersion composition A obtained in Example 1 was used as a G-pigment dispersion composition A, which was then mixed with other components so as to obtain the composition shown in Table 2, to prepare a pigment dispersion photoresist A (colored photosensitive resin composition A).
Pigment dispersion photoresists (colored photosensitive resin compositions) B to C were prepared in the same manner as above, except that the pigment dispersion compositions obtained in Examples 2 to 5 and Comparative Examples 1 and 2 were used in place of the pigment dispersion composition A, respectively.
The pigment dispersion photoresists A to G were each applied onto a glass substrate by using a spin coater and dried at 110° C. for 2 minutes, to form a film having a thickness of about 2 μm. Next, the resultant films were exposed to light from an ultra-high pressure mercury lamp in a stream of nitrogen, and were then developed with a 1% aqueous solution of sodium carbonate. The contrast and Δab* of the obtained films were measured in the same manner as in Example 4. The results are shown in Table 3 below.
It is understood from Table 3 that the pigment dispersion photoresists A to E respectively containing fine particles of the phthalocyanine compound pigments produced by the production method of the present invention are far superior in contrast to the pigment dispersion photoresist F manufactured by an Eiger mill which is usually used in the field concerned and to the pigment dispersion photoresist G in which the pigment is fined by salt milling.
It is also understood that the pigment dispersion photoresists A to E are very superior in light fastness to the pigment dispersion photoresists F and G.
A non-alkali glass substrate was washed by a UV washing device, then brush-washed with a cleaner, and then subjected to ultrasonic washing with ultrapure water. The substrate was heat-treated at 120° C. for 3 minutes to stabilize the surface state.
The substrate was cooled and its temperature was adjusted to 23° C. Then, the substrate was coated with a pigment dispersion photoresist K1 having a composition shown in the following Table 4 by a coater for a glass substrate (trade name: MH-1600 manufactured by FAS Asia) having a slit nozzle. Subsequently, a part of the solvent was removed by drying with a VCD (vacuum drying apparatus; manufactured by Tokyo Ohka Kogyo Co., Ltd.) for 30 seconds to eliminate the fluidity of the coating layer, and the glass substrate was pre-baked at 120° C. for 3 minutes, to give a layer of colored photosensitive resin composition K1 having a film thickness of 2.4 μm.
Using a proximity-type exposure machine having a ultrahigh pressure mercury lump (manufactured by Hitachi High-Tech Electronics Engineering Co., Ltd.), the substrate was pattern-exposed at an exposure of 300 mJ/cm2 with a distance of 200 μm between the photosensitive resin layer and the surface of an exposing mask (quartz exposure mask having an image pattern) while allowing the substrate and the mask to stand straight.
Then, pure water was sprayed through a shower nozzle to uniformly moisten the surface of the photosensitive resin layer K1, and shower developing was performed at 23° C. for 80 seconds with a KOH-based developer (obtained by diluting CDK-1 (trade name) containing KOH and a nonionic surfactant, manufactured by Fuji Film Electronic Materials Co., Ltd., by 1/100) at a flat nozzle pressure of 0.04 MPa to obtain a patterning image. Subsequently, ultrapure water was sprayed through an ultrahigh pressure washing nozzle at a pressure of 9.8 MPa to remove the residue, to obtain a black (K) image K. Subsequently, the substrate having the black image thereon was heat-treated at 220° C. for 30 minutes.
Using a colored photosensitive resin composition R1 having a composition described in Table 5 below, heat-treated R pixels were formed on the substrate having the K image formed thereon, in the same manner as the formation of the black (K) image.
The thickness of the photosensitive resin layer R1, and the coating amounts of the pigments (C.I.P.R.254 and C.I.P.R. 177) are shown below.
Using a colored photosensitive resin composition G1 having a composition described in Table 6 below, heat treated G pixels were formed on the substrate having the K image and R pixels formed thereon) in the same manner as the formation of the black (K) image. The thickness of the photosensitive resin composition G1, and the coating amounts of the pigments (C.I.P.G.36 and C.I.P.Y. 150) are shown below.
Using a colored photosensitive resin composition B1 having a composition described in Table 7 below, heat-treated B pixels were formed on the substrate having the K image, the R pixels, and the G pixels formed thereon, in the same manner as the formation of the black (K) image, so that a desired color filter A was obtained.
The thickness of the photosensitive resin composition B 1, and the coating amounts of the pigments (C.I.P.B. 15:6 and C.I.P.V.23) are shown below.
Herein, preparation of the colored photosensitive resin compositions K1, R1, G1 and B1 described in the above Tables 4 to 7 will be explained.
The colored photosensitive resin composition K1 was obtained by: measuring off the K pigment dispersion 1 and propylene glycol monomethyl ether acetate respectively in the amounts shown in Table 4, then mixing them at a temperature of 24° C. (±2° C.) and stirring the mixture at 150 rpm for 10 minutes, then measuring off methyl ethyl ketone, the binder 2, hydroquinone monomethyl ether, the DPHA liquid, 2,4-bis(trichloromethyl)-6-[4′-(N,N-bisethoxycarbonylmethyl)amino-3′-bromophenyl]-s-triazine, and the surfactant 1 respectively in the amounts shown in Table 4, then adding them to the above mixture in this order at a temperature of 25° C. (+2° C.), and then stirring the resultant mixture at 150 rpm at a temperature of 40° C. (+2° C.) for 30 minutes.
In the composition shown in Table 4, the following components each had the following composition.
The colored photosensitive resin composition R1 was obtained by: measuring off the R pigment dispersion 1, the R pigment dispersion 2, and propylene glycol monomethyl ether acetate respectively in the amounts shown in Table 5, then mixing them at a temperature of 24° C. (+2° C.) and stirring the mixture at 150 rpm for 10 minutes, then measuring off methyl ethyl ketone, the binder 1, the DPHA liquid, 2-trichloromethyl-5-(p-styrylstyryl)-1,3,4-oxadiazole, 2,4-bis(trichlormethyl)-6-[4′-N,N-bisethoxycarbonylmethyl)amino-3′-bromophenyl]-s-triazine, and phenothiazine respectively in the amounts shown in Table 5, then adding them to the above mixture in this order at a temperature of 24° C. (+2° C.) and then stirring the resultant mixture at 150 rpm for 30 minutes, then measuring off the surfactant 1 in the amount shown in Table 5, then adding the surfactant 1 to the mixture at a temperature of 24° C. (+2° C.), then stirring the resultant mixture at 30 rpm for 5 minutes, and then filtering the mixture with a nylon mesh #200.
In the composition shown in Table 5, the R pigment dispersion 1 had the following composition.
The colored photosensitive resin composition G1 was obtained by measuring off the G pigment dispersion A, the Y pigment dispersion 1, and propylene glycol monomethyl ether acetate respectively in the amounts shown in Table 6, then mixing them at a temperature of 24° C. (±2° C.) and stirring the mixture at 150 rpm for 10 minutes, then measuring off methyl ethyl ketone, cyclohexanone, the binder 2, the DPHA liquid, 2-trichloromethyl-5-(p-styrylstyryl)-1,3,4-oxadiazole, 2,4-bis(trichloromethyl)-6-[4′-(N,N-bisethoxycarbonylmethyl)amino-3′-bromophenyl]-s-triazine, and phenothiazine respectively in the amounts shown in Table 6, then adding them to the above mixture in this order at a temperature of 24° C. (+2° C.), then stirring the resultant mixture at 150 rpm for 30 minutes, then measuring off the surfactant 1 in the amount shown in Table 6, then adding the surfactant 1 to the mixture at a temperature of 24° C. (±2° C.), then stirring the resultant mixture at 30 rpm for 5 minutes, and then filtering the mixture with a nylon mesh #200.
Among the compositions shown in Table 6, the G pigment dispersion A was a dispersion obtained in the same manner as the pigment dispersion composition A of Example 1, and was adjusted to include the components in the following amounts (part by mass).
The colored photosensitive resin composition B1 was obtained by: measuring off the B pigment dispersion 1, the B pigment dispersion 2, and propylene glycol monomethyl ether acetate respectively in the amounts shown in Table 7, then mixing them a temperature of 24° C. (±2° C.) and stirring the mixture at 150 rpm for 10 minutes, then measuring off methyl ethyl ketone, the binder 3, the DPHA liquid, 2-trichloromethyl-5-(p-styrylstyryl)-1,3,4-oxadiazole, 2,4-bis(trichloromethyl)-6-[4′-(N,N-bisethoxycarbonylmethyl)amino-3′-bromophenyl]-s-triazine, and phenothiazine respectively in the amounts shown in Table 7, then adding them to the above mixture in this order at a temperature of 25° C. (±2° C.), then stirring the mixture at 150 rpm at a temperature of 40° C. (±2° C.) for 30 minutes, then measuring off the surfactant 1 in the amount shown in Table 7, then adding the surfactant 1 to the mixture at a temperature of 24° C. (±2° C.), then stirring the mixture at 30 rpm for 5 minutes, and then filtering the mixture with a nylon mesh #200.
In the composition shown in Table 7, as the B pigment dispersion 1, “trade name: CF Blue EX3357” manufactured by Mikuni Shikiso Co., Ltd. was used. As the B pigment dispersion 2, “trade name: CF Blue EX3383” manufactured by Mikuni Shikiso Co, Ltd. was used.
The binder 3 had the following composition.
Color filters B and C were manufactured by using the G-pigment dispersion B and G-pigment dispersion C respectively instead of the G-pigment dispersion A in the method of producing the above color filter A. Also, color filters F and G were manufactured by using the G-pigment dispersions F and G of Comparative Examples 1 and 2 respectively instead of the G-pigment dispersion A in the method of producing the above color filter A. The contrasts of the obtained color filters were measured in the same manner as above. The results are shown in Table 8.
The results shown in Table 8 show that the color filters A to C containing the nano-size pigment particles obtained by the production method according to the present invention were extremely superior in contrast to the color filter F containing particles obtained with a commonly-used Eiger mill in this art or the color filter G containing pigment particles fined by salt milling method.
Liquid crystal display devices were prepared respectively by using the color filters A to C, F and G obtained in Example 8, and the display characteristics thereof were evaluated.
A glass substrate having a color filter formed thereon was loaded in a sputter apparatus, and 1300 Å thick ITO (indium tin oxide) was vacuum deposited at 100° C. on the whole surface of the said glass substrate. Thereafter, annealing at 240° C. for 90 minutes was performed, to crystallize the ITO. Thus, ITO transparent electrode was formed.
A spacer was formed on the thus-prepared ITO transparent electrode in the same manner as the spacer-forming method described in Example 1 of JP-A-2004-240335.
Using a coating liquid for a positive type photosensitive resin layer described below, a protrusion for controlling orientation of liquid crystal was formed on the ITO transparent electrode formed with the above-described spacer.
Herein, exposure, development, and bake steps were carried out according to the following method.
A proximity-type exposure equipment (manufactured by Hitachi High-Tech Electronics Engineering Co., Ltd.) was set so that a certain photo mask would be located at the distance of 100 μm from the surface of the photosensitive resin layer. A proximity exposure was carried out through the said photo mask in an exposure energy of 150 mJ/cm2 using an ultra-high pressure mercury lamp.
Subsequently, development was conducted by spraying a 2.38% tetramethyl ammonium hydroxide solution on to the substrate at 33° C. for 30 seconds using a shower-type developing apparatus. In this manner, unnecessary portions (exposed portions) of the photosensitive resin layer were removed by development. Thereby, on the substrate at the same side as the color filter, was formed the objective protrusion for controlling orientation of liquid crystal that was made by patterning the photosensitive resin layer into a desired shape.
After that, the substrate for a liquid crystal display device having formed thereon the protrusion for controlling orientation of the liquid crystal was baked under the conditions of 230° C. for 30 minutes. Thereby, a cured protrusion for controlling orientation of the liquid crystal was formed on the substrate for a liquid crystal display device.
An alignment film composed of polyimide was further provided on the thus-obtained substrate for a liquid crystal display device. Thereafter, a sealing agent made of an epoxy resin was printed at the positions corresponding to the outer frame of the black matrix that was disposed so as to surround the periphery of the pixels of the color filter. In addition, after dropping thereon a liquid crystal for MVA-mode, the above-described substrate and a counter substrate were stuck together. The stuck substrates were subjected to a thermal processing to cure the sealing agent. On each surface of the thus-obtained liquid crystal cell, a polarizing plate (G1220DUN manufactured by Nitto Denko Corp.) was stuck together. Subsequently, a backlight with a three-wavelength cold-cathode tube light source (FWL18EX-N manufactured by Toshiba Lighting & Technology Corporation) was formed, and the backlight was set at the back side of the liquid crystal cell provided with the polarizing plates. Thus, the liquid crystal display device was produced.
The liquid crystal display devices using the color filters A to C of the present invention respectively were superior to the liquid crystal display devices using the color filters F and G of Comparative Examples in the blackness and depiction of green and exhibited better display characteristics.
A thermoplastic resin layer coating liquid having the following formulation Hi was coated on a polyethylene terephthalate film temporary support with a thickness of 75 μm using a slit nozzle, followed by drying. Then, an intermediate layer coating liquid having the following formulation P1 was coated thereon, and dried. Further, the same colored photosensitive resin composition K1 as that in Example 8 was applied and dried. In this manner, a thermoplastic resin layer having a dry film thickness of 14.6 μm, an intermediate layer having a dry film thickness of 1.6 μm, and a photosensitive resin layer having a dry film thickness of 2.4 μm were provided on the temporary support. Then, a protective film (polypropylene film having a thickness of 12 μm) was adhered to the photosensitive resin layer under pressure.
In this manner, a photosensitive resin transfer material in which the temporary support, thermoplastic resin layer, intermediate layer (oxygen blocking film) and black (K) photosensitive resin layer were integrated was manufactured, and this sample was designated as photosensitive resin transfer material K1.
Photosensitive resin transfer materials R101, G101 and B101 were produced in the same manner as the production of the photosensitive resin transfer material K1, except that the colored photosensitive resin composition K1 used in production of the photosensitive resin transfer material K1 was replaced respectively by colored photosensitive resin compositions R101, G101 or B101 having the compositions shown in Tables 9 to 11 below. The methods for producing the colored photosensitive resin compositions (pigment dispersion photoresist) R101, G101 and B101 were similar to the methods for producing the colored photosensitive resin compositions (pigment dispersion photoresist) R1, G1 or B1, respectively.
In the compositions shown in Table 9, as the additive 1, a phosphoric-ester-based special surfactant (trade name: HIPLAAD ED152, manufactured by Kusumoto Chemicals Ltd.) was used.
A non-alkali glass substrate was washed with a rotating brush having nylon hairs while spraying a glass cleaner liquid regulated at 25° C. by a shower for 20 seconds, then the glass substrate was washed with pure water shower. Thereafter, a silane coupling solution (a 0.3 mass % aqueous solution of N—P(aminoethyl)γ-aminopropyltrimethoxysilane, trade name: KBM603, manufactured by Shin-Etsu Chemical Co., Ltd.) was sprayed for 20 seconds by a shower, and the substrate was washed with a pure water shower. This substrate was heat-treated by a substrate pre-heating apparatus at 100° C. for 2 minutes, and was supplied to the next laminator.
The protective film of the photosensitive resin transfer material K1 was peeled off, and the substrate heated to 100° C. was laminated with the photosensitive resin transfer material K1 at a rubber roller temperature of 130° C., a linear pressure of 100 N/cm, and a conveying rate of 2.2 m/min, using a laminator (Lamic II type, manufactured by Hitachi Industries Co., Ltd.).
After the temporary support was peeled off at the interface with the thermoplastic resin layer; the thermoplastic resin layer was pattern-exposed at an exposure intensity of 70 mJ/cm2, in a proximity exposure machine (manufactured by Hitachi High-Technologies Corp.) having an ultrahigh-pressure mercury lamp, in a condition where the support and the mask (a quartz exposure mask having an image pattern) were placed to stand vertically and the distance between the exposure mask surface and the thermoplastic resin layer was set to 200 μm.
Then, shower development was performed with a triethanolamine-based developer (containing 30% triethanolamine, T-PD2, trade name, a product of Fuji Photo Film Co., Ltd., diluted by 1/12 with purified water (or a dilute solution obtained by adding 11 parts of purified water to 1 part T-PD2)) at 30° C. for 50 seconds at a flat nozzle pressure of 0.04 MPa, so that the thermoplastic resin layer and the interlayer were removed.
Subsequently, using a sodium-carbonate-based developer (containing 0.38 mol/l of sodium bicarbonate, 0.47 mol/l of sodium carbonate, and 5% of sodium dibutylnaphthalenesulfonate, an anionic surfactant, an anti-foaming agent, and a stabilizer, trade name: T-CD1, manufactured by Fuji Photo Film Co., Ltd., diluted by 1/5 with purified water), another shower developing was performed at 29° C. for 30 seconds under a cone-type nozzle pressure of 0.15 MPa, to develop the photosensitive resin layer, so that the patterning image was obtained.
Subsequently, using a cleaner (a dilute solution containing T-SD3, trade name, manufactured by Fuji Photo Film Co., Ltd., diluted by 1/10 with purified water), the residue was removed by a shower and a rotating brush having nylon hairs at 33° C. for 20 seconds under a cone-type nozzle pressure of 0.02 MPa, so that a black (K) image was obtained. Thereafter, after the substrate was subjected to post exposure to light of 500 mJ/cm2 from the resin layer side emitted by an ultrahigh pressure mercury lamp, heat-treatment was performed at 220° C. for 15 minutes.
The substrate having the K image formed thereon was washed with a brush in the same manner as described above, and then washed with pure water shower, and then supplied to a substrate pre-heating apparatus without using a silane coupling liquid.
Heat-treated red (R) pixels were obtained by using the photosensitive resin transfer material R101, in the same steps as the photosensitive resin transfer material KI was processed. The exposure was 40 mJ/cm2, and the development with the sodium-carbonate-based developer was performed at 35° C. for 35 seconds.
The thickness of the photosensitive layer R101, and the coating amounts of the pigments (C.I.P.R.254 and C.I.P.R.177) are shown below.
The substrate having the K image and the R pixels thereon was washed again with a brush in the same manner as described above, and washed with pure water shower, and supplied to a substrate pre-heating apparatus without using a silane coupling liquid.
Heat-treated green (G) pixels were obtained by using the photosensitive resin transfer material G101, in the same steps as the photosensitive resin transfer material R101 was processed. The exposure was 40 mJ/cm2, and the development with the sodium-carbonate-based developer was performed at 34° C. for 45 seconds.
The thickness of the photosensitive layer G101 and the coating amounts of the pigments (C.I.P.G.36 and C.I.P.Y.150) are shown below.
This substrate having the K image, the R pixels, and G pixels thereon was washed again with a brush in the same manner as described above, then washed with pure water shower, then supplied to the substrate pre-heating apparatus without using a silane coupling liquid.
Heat-treated blue (B) pixels were obtained by using the photosensitive resin transfer material B101 in the same manner as the formation of the red (R) image with the photosensitive resin transfer material R101. The exposure was 30 mJ/cm2, and the development with the sodium-carbonate-based developer was performed at 36° C. for 40 seconds.
The thickness of the photosensitive resin layer B101 and the coating amounts of the pigments (C.I.P.B.15:6 and C.I.P.V.23) are shown below.
This substrate having the K image, the R pixels, the G pixels, and the B pixels thereon was baked at 240° C. for 50 minutes to obtain a color filter A1.
In the method of producing the above color filter A1, the concentrated pigment liquid A having a paste form was altered to the concentrated pigment liquids B and C each having a paste form in Examples 2 and 3, and the G pigment dispersion B and G pigment dispersion C were used in place of the G pigment dispersion A, to manufacture color filters B1 and C1 respectively. Also, in the method of producing a color filter, the G pigment dispersion A was altered to the pigment dispersion compositions F and G of Comparative Examples 1 and 2, to manufacture color filters F1 and G1 respectively.
The contrast (R component) of each of the obtained color filters was measured in the same manner as above. The results are shown in Table 12.
The results shown in Table 12 show that the color filters A1 to C1 containing the fine particles of the phthalocyanine compound pigments obtained by the production method according to the present invention were extremely superior in contrast to the color filter F1 containing particles obtained with a commonly-used Eiger mill in this art or the color filter G1 containing pigment particles fined by salt milling method.
Liquid crystal display devices were prepared in the same manner as in Example 9, by using the color filters A1 to C1 and F1 to G1 obtained in Example 10 respectively, and the display characteristics thereof were evaluated. The liquid crystal display devices prepared by using the color filters A1 to C1 according to the present invention had favorable display characteristics, superior display blackness and depiction of green, compared to the liquid crystal display devices prepared by using the color filters F1 to G1 for comparison.
20.0 ml of a 28% solution of sodium methoxide in methanol, 30 g of a pigment C.I. Pigment Green 36 (Lionol Green 6YK, trade name, manufactured by Toyo Ink Mfg Co., Ltd.), and 70.0 g of polyvinyl pyrrolidone (K-30, trade name, manufactured by Wako Pure Chemical Industries, Ltd.) were added to 800 ml of dimethyl sulfoxide (manufactured by Wako Pure Chemical Industries, Ltd.), to prepare a pigment solution GL. The viscosity of the pigment solution GL, as determined by using Viscomate VM-10A-L (trade name, manufactured by CBC Materials), was 15.0 mPa·s, when the liquid temperature of the pigment solution GL was 22.0° C. Separately, 800 ml of water containing 12 ml of 1-mol/l hydrochloric acid (manufactured by Wako Pure Chemical Industries, Ltd.) was prepared as a poor solvent
100 ml of the pigment solution GL was fed through a feed pipe having a channel diameter of 0.8 mm, as driven by a NP-KX-500 large-volume pulse-free pump (trade name, manufactured by Nihon Seimitsu Kagaku Co., Ltd.), at a flow rate of 100 ml/min into 800 ml of water as the poor solvent controlled to a temperature of 22° C. and being stirred at 500 rpm by a GK-0222-10 Ramond stirrer (trade name, manufactured by Fujisawa Pharmaceutical Co., Ltd.), thereby forming organic pigment paiticles, to give a pigment dispersion GL. The number-average particle diameter n and the monodispersion degree (Mv/Mn) thereof were determined by using Nanotrack UPA-EX150 (trade name, manufactured by Nikkiso). Results are shown in the following Table 13.
The pigment nanoparticle dispersion prepared by the method above was concentrated through a filter cloth P89C manufactured by Shikishima Canvas Co., Ltd. in H-110A centrifugal filtration machine manufactured by Kokusan Co., Ltd., at 3,000 rpm for 160 minutes, and the pigment nanoparticle concentrated paste obtained was recovered.
The pigment content in the paste, as determined by using type 8453 spectrophotometer manufactured by Agilent, was 14.0 wt %.
A solution containing 0.2 g of the pigment-dispersing agent A prepared according to the method described in JP-A-2000-239554 and 2.3 g of a polymer compound C-1 dissolved in 50.0 cc of ethyl lactate was added to 16.0 g of the pigment nanoparticle paste prepared; the mixture was agitated at 1,500 rpm for 60 minutes with a dissolver and then filtered through a FP-010 filter manufactured by Sumitomo Electric Fine Polymer Inc., to give a paste-like concentrated pigment liquid GL (nano-size pigment concentration: 33.5 mass %).
A pigment dispersion composition GL in the following composition was preparation by using the aforementioned paste.
The resultant pigment dispersion composition was dispersed with using zirconia beads of 0.65 mm in diameter, at a peripheral speed of 9 m/s, for 1 hour, using a motor mill M-50 (manufactured by Eigar Japan).
A pigment dispersion composition GM was preparation in the same manner as in Example 12-1, except that the channel diameter of the feeding pipe for injection of the pigment solution GL in Example 12-1 was changed to 0.25 mm and the injection flow rate to 8 ml/min. The number-average particle diameter and the monodispersion degree of the pigment dispersion GM prepared were determined, in the same manner as in Example 12-1.
A pigment dispersion composition GN was preparation in the same manner as in Example 12-1, except that the channel diameter of the feeding pipe for injection of the pigment solution GL in Example 12-1 was changed to 2.20 mm and the injection flow rate to 400 ml/min. The number-average particle diameter and the monodispersion degree of the pigment dispersion GN prepared were determined, in the same manner as in Example 12-1.
A pigment dispersion composition GO was prepared in the same manner as in Example 12-1, except that the polymer compound C-1 used in preparation of the pigment dispersion preparation in Example 12-1 was replaced with 5.75 of a methacrylic acid/benzyl methacrylate copolymer (molar ratio: 28/72, weight-average molecular weight 30,000, 40% 1-methoxy-2-propyl acetate solution) and the addition amount of 1,3-butylene glycol diacetate was changed to 40.45 g.
In the following manner, a pigment dispersion composition GP having the composition described below was prepared with a beads-mil dispersing machine.
In the following manner, a pigment dispersion composition GQ having the composition described below was prepared.
Sodium chloride, a pigment powder (pigment green 36), and a methacrylic acid/benzyl methacrylate copolymer were added to 1,3-butylene glycol diacetate solution, and the mixture was kneaded in a double-screw kneader at 80° C. for 10 hours. After kneading, the mixture was taken to 500 mass parts of 1 mass % hydrochloric acid aqueous solution of 80° C., and then stirred for 1 hour, followed by filtration, washing with a hot water, drying, and grinding. Thereafter, 2.4 g of 1,3-butylene glycol diacetate per 1 g of the ground product were added and mixed. The resultant pigment composition was dispersed with using zirconia beads of 0.65 mm in diameter, at a peripheral speed of 9 m/s, for 1 hour, using a motor mill M-50 (manufactured by Eigar Japan). The thus-obtained pigment dispersion composition was designated as pigment dispersion composition GQ.
The particle diameters and monodispersion degrees determined in Examples 12-1 to 12-4 and Comparative Examples 12-1 and 12-2 are summarized in the following Table 13.
It is understood from this results that according to the production method of the present invention, nanoparticles having a desired particle diameter and degree of monodispersion can be obtained by regulating the condition under which the pigment particles are formed.
A thermoplastic resin layer coating liquid having the following formulation H3 was coated on a polyethylene terephthalate film temporary support with a thickness of 75 μm using a slit nozzle, followed by drying. Then, an intermediate layer coating liquid having the following formulation P3 was coated thereon, and dried. Further, the resin composition K3 having a light-blocking property and having the formulation shown in Table 14, was coated and dried thereon. The resultant temporary support was provided with the thermoplastic resin layer having a dry film thickness of 15 μm, the intermediate layer having a dry film thickness of 1.6 μm and the light-blocking resin layer having a dry film thickness of 2.4 μm. A protective film (polypropylene film having a thickness of 12 μm) was bonded thereon under pressure additionally.
In the above described procedure, a photosensitive resin transfer material was produced in which the temporary support, the thermoplastic resin layer, the intermediate layer (oxygen blocking film) and the light-blocking resin layer were unified; and it was designated as photosensitive resin transfer material K3.
*Formulation H3 for thermoplastic resin layer coating liquid.
*Composition of Surfactant 1B (Megafac F-780-F (manufactured by DIC Corporation))
*Formulation P3 for intermediate layer (oxygen blocking layer) coating liquid
Herein, preparation of the light-shielding resin composition K3 shown in the above Table 14 is explained below.
The light-shielding resin composition K3 was prepared as follows: First, the K pigment dispersion 3 and propylene glycol monomethyl ether acetate were weighed out in the amounts shown in Table 14, respectively, and mixed together at a temperature of 24° C. (±2° C.), and her stirred at 150 rpm for 10 minutes. Then, methyl ethyl ketone, Binder 5, hydroquinone monomethyl ether, the DPHA liquid, 2,4-bis(trichloromethyl)-6-[4′-(N,N-bisethoxycarbonylmethyl)amino-3′-bromophenyl]-s-triazine and the surfactant 1B were weighed out in the amounts shown in Table 14, respectively, and added to the foregoing mixture in sequence in the described order at a temperature of 25° C. (±2° C.), and further stirred at 150 rpm for 30 minutes at a temperature of 40° C.
In the composition shown in Table 14,
the K pigment dispersion 3 had the following composition:
the binder 5 had the following composition:
the DPHA liquid had the following composition:
Incidentally, the surfactant 1B was identical with the surfactant 1B used in the thermoplastic resin layer coating solution H3.
A non-alkali glass substrate was washed with a rotating brush having nylon hairs while spraying a glass cleaner liquid regulated at 25° C. by a shower for 20 seconds, then the glass substrate was washed with pure water shower. Thereafter, a silane coupling solution (a 0.3 mass % aqueous solution of N—P(aminoethyl)γ-aminopropyltrimethoxysilane, trade name: KBM603, manufactured by Shin-Etsu Chemical Co., Ltd.) was sprayed for 20 seconds by a shower, and the substrate was washed with a pure water shower. This substrate was heat-treated by a substrate pre-heating apparatus at 10° C. for 2 minutes.
The protective film of the photosensitive resin transfer material K3 was peeled off, and the substrate heated to 100° C. for 2 minutes was laminated with the photosensitive resin transfer material K3 at a rubber roller temperature of 130° C., a linear pressure of 100 N/cm, and a conveying rate of 2.2 ml/min, using a laminator (Lamic II type, manufactured by Hitachi Industries Co., Ltd.).
After the temporary support was peeled off, the photosensitive resin was pattern-exposed by using a proximity-type exposure machine having an ultrahigh pressure mercury lamp (manufactured by Hitachi High-Tech Electronics Engineering Co., Ltd) at an exposure of 100 mJ/cm2 with a distance of 200 μm between the photosensitive resin layer and the surface of the exposure mask (quartz exposure mask having image pattern), while allowing the substrate and the mask to stand straight. The mask used herein had a grid pattern, in which the radii of curvature of a salient angle on the side of the light-shielding barrier rib in the part corresponding to the boundary between each pixel and each light-shielding barrier rib was 0.6 μm.
Next, a triethanolamine type developer (trade name: T-PD1, manufactured by Fuji Photo Film Co., Ltd., the developer contains 2.5% triethanolamine, a nonionic surfactant and a polypropylene type antifoaming agent) was used to carry out shower-developing in the following conditions, 30° C., 50 seconds, flat nozzle pressure: 0.04 MPa, to remove the thermoplastic resin layer and intermediate layer (oxygen blocking layer).
In succession, a sodium carbonate type developer (trade name: T-CD1, manufactured by Fuji Photo Film Co., Ltd., the developer contains 0.06 mol/l of sodium bicarbonate, sodium carbonate having the same concentration, 1% of sodium dibutylnaphthalenesulfonate, anionic surfactant, antifoaming agent and a stabilizer) was used to carry out shower-developing in the following conditions, 29° C., 30 seconds, cone-type nozzle pressure: 0.15 MPa, to develop the resin layer having light-shielding ability and thereby to obtain a barrier rib patterning (a partition-wall pattern having light-shielding ability).
In succession, a cleaner (trade name: “T-SD1”, manufactured by Fuji Photo Film Co., Ltd., the cleaner contains a phosphate, a silicate, a nonionic surfactant, an antifoaming agent, and a stabilizer) was used to remove residues with using a rotary brush having a shower and a nylon hair, in the following conditions: 33° C., 20 seconds and cone type nozzle pressure: 0.02 MPa, to obtain a light-shielding barrier rib. Thereafter, the substrate was post-exposed to light of a ultra-high pressure lamp from the resin layer side with respect to the substrate at a dose of 500 mJ/cm2 and then heat-treated at 240° C. for 50 minutes.
Thereafter, water-repellency-providing plasma treatment was performed in the following manner.
The light-shielding barrier rib-formed substrate was subjected to water-repellency-providing plasma treatment using a cathode-coupling parallel-plate plasma treatment apparatus under the following conditions;
Gas used: CF4
Rate of gas flow: 80 seem
RF power; SOW
Treatment time: 30 see
An ink was prepared by the method described in Example 1 of JP-A-2002-201387.
The mixing of the ingredients shown in Table 15 was carried out as follows: First, the pigment and the polymeric dispersant were charged into a part of the solvent, mixed and stirred with a three-rod roll and a beads mill, thereby preparing a pigment dispersion liquid. Separately, the other ingredients were charged into the remainder of the solvent, dissolved and dispersed with stirring, thereby preparing a binder solution. Then, the pigment dispersion liquid or the pigment dispersion composition was added little by little to the binder solution while thoroughly stirring the resulting mixture with a dissolver. Thus, an inkjet ink for color filter was prepared.
The R ink 11, the G ink 11 and the B ink 11 obtained above were first ejected into dents surrounded by the light-shielding barrier rib by using a piezoelectric head in the following manner, to give a color filter according to the present invention in the following way.
The head had 318 nozzles at a nozzle density of 150 nozzles per 25.4 mm in two nozzle row directions placed in parallel at a displacement of half nozzle gap, which eject 300 droplets per 25.4 mm of ink on the substrate in the nozzle placement direction.
The head and the ink were so controlled by circulation of hot water in the head that the temperature of the ink ejection region was kept at 50±0.5° C.
Ink ejection from the head was controlled by the piezoelectric drive signal sent to the head, to eject a droplet in an amount of 6 to 42 pl, and the ink was ejected in the present Example from the head onto a glass plate, while conveying the plate at the position 1 mm below the head. The conveying speed was adjustable in the range of 50 to 200 mm/s. The piezoelectric drive frequency may be raised up to 4.6 KHz, and the droplet quantity can be controlled by the setting.
The R, G, and B inks were ejected into the dents corresponding to the desired R, G and B colors, as the traveling speed and the drive frequency were so controlled that the coating amounts of the R, G, and B pigments would be respectively 1.1, 1.8, and 0.75 g/m2.
The ejected ink is conveyed to the exposure unit, where it is irradiated by the light from a ultraviolet light-emitting diode (UV-LED). The UV-LED used was NCCU033 manufactured by Nichia Corporation. The LED emits a UV light at a wavelength of 365 nm from one chip, and the chip emits a light at an intensity of approximately 100 mW upon application of a current of approximately 500 mA. Multiple chips were placed at an interval of 7 mm, giving a total power of 0.3 W/cm2 on the surface. The period from ink ejection to light exposure and the exposure period can be changed according to the medium conveying speed and the distance between the head and the LED. The ink after ejection was dried at 100° C. for 10 minutes and then subjected to exposure to light.
The light-exposure energy on the medium may be adjusted in the range of 0.01 to 15 J/cm2 according to the settings of the distance and the conveying speed. The light-exposure energy was adjusted based on the conveying speed.
The exposure power and the light-exposure energy were determined by using a spectroradiometer URS-40D manufactured by Ushio Inc., and the integral values in the wavelength range of 220 nm to 400 nm were used.
The glass plate after ink ejection was baked in an oven at 230° C. for 30 minutes, for complete hardening of the light-shielding barrier rib and respective pixels.
A liquid crystal display device GL was prepared in the same manner as in Example 9 by using the color filter prepared in the above.
Liquid crystal display devices GM to GQ were prepared in the same manner as the liquid crystal display device GL, except that the R ink 11 used in preparation of the liquid crystal display device GL was replaced with G inks 12 to 16, respectively.
The contrast of each of the pigment dispersion compositions GL to GQ prepared in Examples 12-1 to 12-4 and Comparative Examples 12-1 and 12-2 was determined, in the same manner as described above.
The display characteristics of the liquid crystal display devices prepared were evaluated by ten examiners, from the points of display blackness and green reproducibility. The averages of 10 results according to the following 5 criteria are shown in Table 16. It is understood that the liquid crystal display devices GL to GO according to the present invention had display characteristics overwhelmingly superior to those in Comparative Examples GP and GQ.
The nano-size phthalocyanine-series pigment fine particles obtained by the production method of the present invention enable the production of a pigment dispersion composition excellent in dispersibility and fluidity. Further, the pigment dispersion photoresist and colored transfer material according to the present invention can exhibit high color density even with a thin film thickness and is therefore suitable for applications such as image formation materials used to form color proof, color filter, and the like. Further, the color filter of the present invention has excellent contrast and light fastness and is therefore suitable for applications such as liquid crystal display devices. Further, the liquid crystal display device of the present invention enables a high discrimination of brightness from darkness and is therefore excellent in black depth.
Having described our invention as related to the present embodiments, it is our intention that the invention not be limited by any of the details of the description, unless otherwise specified, but rather be construed broadly within its spirit and scope as set out in the accompanying claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2006-024630 | Feb 2006 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2006/322308 | 11/8/2006 | WO | 00 | 7/31/2008 |
