High refractive index nanocomposites

• US 10,377,913 B2
• Filed: 09/08/2017
• Issued: 08/13/2019
• Est. Priority Date: 09/16/2016
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Lyon, Jennifer Lynn, Maurey, Pamela Arlene, Senaratne, Wageesha, Weikel, Arlin Lee, Zhang, Ying
• Primary Examiner(s): Whiteley, Jessica
• Application Number:
  US15/699,493
• Publication Number:
  US 20180079925A1
• Time in Patent Office: 704 Days
• Field of Search: 522 64, 522 71, 522189, 522184, 522 1, 522 6, 520 1
• CPC Class Codes: C08K 7/16 Solid spheres
• CPC Class Codes: C08L 2666/54 Inorganic substances
• CPC Class Codes: C08L 33/08 Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08L 33/10 Homopolymers or copolymers of methacrylic acid esters
• CPC Class Codes: C09D 133/02 Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: C09D 133/04 Homopolymers or copolymers of esters C09D143/04 takes precedence
• CPC Class Codes: C09D 4/00 Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
• CPC Class Codes: G02B 1/04 made of organic materials, e.g. plastics G02B1/08 takes precedence
• CPC Class Codes: G02B 1/045 Light guides
• CPC Class Codes: G02B 6/1221 made from organic materials
• CPC Class Codes: G02B 6/124 Geodesic lenses or integrated gratings

Abstract

A composite coating having a high refractive index, high Abbe number, low haze and high transmittance, suitable for fabricating nanoscale optical surface features includes a resin with a crosslinked polymer matrix having polymers with repeat units derived from acrylic or methacrylic monomers or oligomers and inorganic nanoparticles disposed within the resin, wherein the composite coating has a refractive index equal to or greater than 1.7 and a glass transition temperature equal to or greater than 60° C.

Claims

1. A composite coating comprising:

a resin including a polymer network, the polymer network including repeat units derived from an acrylic or methacrylic monomer or oligomer; and

inorganic nanoparticles disposed within the resin,

wherein the composite coating has a refractive index greater than 1.7 and a glass transition temperature greater than 60°

C., and

wherein the polymer network comprises from 25 wt % to 60 wt % repeat units derived from a trifunctional acrylic or methacrylic monomer or oligomer, 40 wt % or more repeat units derived from bifunctional acrylic or methacrylic monomers or oligomers, and, optionally up to 10 wt % repeat units derived from monofunctional monomers or oligomers.

2. The composite coating of claim 1, wherein the polymer network comprises repeat units derived from two or more acrylic or methacrylic monomers or oligomers.

3. The composite coating of claim 1, wherein the coating has an Abbe number greater than 29.0.

4. The composite coating of claim 1, wherein the weight ratio of resin to inorganic nanoparticles in the composite coating is in the range from 1:

5 to 1;

1.

5. The composite coating of claim 1, wherein the polymer network comprises at least 90% wt % repeat units derived from bifunctional, polyfunctional or a combination of bifunctional and polyfunctional acrylic or methacrylic monomers or oligomers.

6. The composite coating of claim 1, wherein the trifunctional acrylic or methacrylic monomers or oligomers include tris(2-hydroxyethyl isocyanurate) triacrylate;

and the bifunctional acrylic or methacrylic monomers or oligomers includes at least one of an aliphatic urethane difunctional acrylate monomer or oligomer, or an aromatic urethane difunctional acrylate monomer or oligomer.

7. The composite coating of claim 6, further including a monofunctional repeat unit that is the residue of at least one monomer wherein the polymer network includes a repeat unit derived from n-vinyl caprolactam or fluorine diacrylate.

8. The composite coating of claim 1, wherein the polymer network comprises from 50 wt % to 100 wt % of repeat units derived from bifunctional acrylic or methacrylic monomers or oligomers, optionally up to 50 wt % of repeat units derived from trifunctional acrylic or methacrylic monomers or oligomers, and optionally up to 10 wt % of repeat units derived from monofunctional monomers or oligomers.

9. The composite coating of claim 8, wherein the bifunctional acrylic or methacrylic monomers or oligomers include fluorene diacrylate (9,9-bis[4-(2-acryloyloxyethyl)phenyl] fluorine) or a urethane bifunctional acrylate oligomer.

10. The composite coating of claim 9, wherein the polymer network includes a repeat unit derived from tris(2-hydroxyethyl isocyanurate) triacrylate.

11. The composite coating of claim 9, wherein the polymer network includes a repeat unit derived from acrylic acid or hydroxybutyl acrylate.

12. The composite coating of claim 1, wherein the inorganic nanoparticles comprise zirconium oxide.

13. The composite coating of claim 12, wherein the zirconium oxide nanoparticles have an average size of about 10 nm or less.

14. The composite coating of claim 1, wherein the inorganic nanoparticles are chemically bonded to the polymer network.

15. The composite coating of claim 1, further including a surface diffraction grating.

16. The composite coating of claim 1, wherein the composite coating has a transmittance greater than 90% and a haze less than 0.3%.