Zirconium Oxide Dispersion Process for Optical Materials
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Solution Overview
Problem
Current processes for producing dispersion of fine inorganic particles for optical members face challenges such as low productivity, overdispersion, and decreased refractive index, particularly when using small particle size media and high amounts of dispersants, which are costly and limit available machines.
Innovation Solution
A process involving a media type wet dispersing machine where zirconium oxide nanoparticles, a silane coupling agent, and a dispersion medium are supplied first, followed by a dispersant, to achieve stable dispersion with high solid concentration without overdispersion, thereby shortening the dispersion process time and maintaining high refractive index.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If small particle size media (30 μm or less) are used to prevent overdispersion, then manufacturing precision is improved, but device complexity increases and availability of dispersing machines is limited
Solution Approach 1:
The invention changes the particle size parameter of dispersing media from small (30 μm or less) to large (greater than 30 μm), which fundamentally alters the dispersion mechanism to achieve fine particle dispersion without requiring complex equipment. This parameter reversal resolves the contradiction by maintaining manufacturing precision while reducing device complexity requirements.
2Manufacturing precision
If solid concentration is lowered to prevent overdispersion, then manufacturing precision is improved, but productivity deteriorates due to significantly prolonged process time
Solution Approach 1:
The invention changes the solid concentration parameter from low concentration to high concentration conditions, combined with using large particle size media. This parameter change allows the system to achieve uniform dispersion at high solid concentration while maintaining short process times, thereby resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The invention performs preliminary classification of dispersed particles into coarse and fine fractions, where coarse particles are removed and fine particles are retained. This preliminary action enables the system to achieve high manufacturing precision by removing oversized particles while maintaining high productivity through efficient separation mechanisms.
3Reliability
If large amount of dispersants are used to achieve stable dispersion, then reliability is improved, but refractive index of the obtained cured composition is decreased
Solution Approach 1:
The invention uses a small amount of dispersant that performs its function efficiently during the dispersion process. The dispersant is used in minimal quantities compared to conventional approaches, yet achieves sufficient dispersion stability. This resolves the contradiction by maintaining reliability through effective dispersant usage while preserving refractive index by minimizing dispersant content in the final composition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a cured material with a high refractive index and stable dispersion using a small amount of dispersant, significantly reducing the dispersion process time without overdispersion, and avoiding the limitations of expensive and limited small particle size media.
Implementation Method 1
supplying a silane coupling agent last among the respective materials, that is, a zirconium oxide nanoparticle, a dispersant, a dispersion medium, and the silane coupling agent to be supplied to the media type wet dispersing machine
Implementation Method 2
a process for producing dispersion of fine inorganic particles by using a media type wet dispersing machine
Data Source
AI summary
Provided are a cured material having a high refractive index for an optical member obtained by preparing a stable dispersion with a small amount of dispersant, and a process for producing dispersion of fine inorganic particles which is capable of drastically shortening the dispersion process time without causing overdispersion under the conditions of high solid concentration and without using media having a small particle size, which are very expensive and for which available dispersing machines are limited. Provided are a process for producing dispersion of fine inorganic particles using a media type wet dispersing machine, which includes supplying the following (A) to (D) to the wet dispersing machine, provided that (D) is supplied last to the wet dispersing machine:(A) Zirconium oxide nanoparticle,(B) Silane coupling agent,(C) Dispersion medium, and(D) Dispersant;a curable composition containing a dispersion obtained by the producing process; and a cured material obtained therefrom.