CN100380703C - 吸湿板 - Google Patents
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Abstract
本发明涉及一种含有少量具有较高重均分子量的有机聚合物和大量吸湿材料颗粒的吸湿板，特别是所述聚合物为重均分子量大于1百万的超高分子量聚合物。尽管吸湿材料的含量较高，然而根据本发明的吸湿板不容易形成裂纹和分解，并具有较高的孔隙率。由于这些特性，根据本发明的吸湿板对于在有机电致发光器件中的应用尤其有用。
Description
技术领域
本发明涉及一种吸湿板、一种制造吸湿板的方法，以及一种包括有这种吸湿板的有机电致发光器件。
背景技术
在美国专利US5124204中公开了一种吸湿板，其包括有机聚合物和分散在有机聚合物中的吸湿材料颗粒。此处公开的吸湿板包括带有以预定表面密度分散在其中的硅胶粉的有机聚合物板(例如天然聚合物、改性天然聚合物和合成聚合物)。这种硅胶粉为可与水粘合的干燥物。
在美国专利US5124204中还公开了在薄膜电致发光(EL)板中使用这种吸湿板。EL板包括可透光的基板、形成于基板上的薄膜EL元件，以及覆盖在薄膜EL元件上以防止湿气到达EL元件的防潮板。所述EL元件还可由设置于所述薄膜EL元件和所述防潮板之间的所述吸湿板来防止湿气。或者，可通过在防潮板上朝向薄膜EL元件的表面上设置吸湿层来实现吸湿板的效果。
这种现有技术的吸湿板的缺点在于，在实际中吸湿材料的含量增加会导致吸湿板的集成度下降，并使吸湿板易于形成裂纹和分解。
发明内容
本发明的目的之一是提供一种吸湿板，其包括尽管吸湿材料的含量较高也能缠结和固定住吸湿材料颗粒的有机聚合物。
为此，本发明的第一方面提供了一种吸湿板。本发明的第二方面提供了制造吸湿板的几种方法。本发明的第三方面提供了一种包括有根据本发明的吸湿板的有机电致发光器件。
本发明的吸湿板包括吸湿材料颗粒，其与相对较少量的具有高重均分子量的聚合物相结合。聚合物为重均分子量大于1百万的有机超高分子量(UHMW)聚合物。UHMW聚合物与吸湿材料颗粒互连，使得尽管吸湿材料的含量较高，但是吸湿板仍不容易形成裂纹和分解。结果是，本发明的吸湿板是自支撑的。这种自支撑板是非常有利的，因为它们易于进行处理。例如，可以从板中切出预定的形状，这种形状确定了吸湿材料的用量和分布。
采用根据本发明的UHMW聚合物，就可以制造出具有大量吸湿材料颗粒的吸湿板。在本发明的一个优选实施例中，吸湿板含有80到99.9％重量(重量百分比)的吸湿材料颗粒和0.1到20.0％重量的UHMW聚合物。最好，吸湿材料板含有95到99.9％重量的吸湿材料颗粒和0.1到5.0％重量的UHMW聚合物。
根据本发明的吸湿板的另一优点是吸湿板可具有较高的孔隙率。在根据本发明的吸湿板中可容易地实现至少30％体积的孔隙率。与压实的吸湿板相比，这种孔隙率可使水分子能容易地接近更多的吸湿材料颗粒。由于此孔隙率，吸湿物质具有提高的吸湿性能。
在一个优选实施例中，聚合物含有平均分子量大于1百万的UHMW聚合物。少量的这种UHMW聚合物能够将可形成薄的柔性自支撑吸湿板的吸湿材料颗粒互连，这样，尽管吸湿材料的含量较高，然而吸湿板不容易形成裂纹和分解。
UHMW聚合物最好为线性聚合物。这种具有较高重均分子量的线性聚合物可在溶液中相对较低的聚合物浓度下形成缠结，这就使得可形成能将吸湿材料颗粒固定在一起的网络。
为了得到具有较高温度稳定性的吸湿板，希望聚合物是可交联的。可以用例如电磁辐射、电离辐射或电子束形式的能量辐射来进行交联。所述转变最好通过紫外线辐射来进行。
具有较高重均分子量的有机聚合物最好从由聚乙烯、聚丙烯、聚苯乙烯、聚环氧乙烷、聚环氧丙烷、聚丙烯酸酯、聚碳酸酯、聚甲基丙烯酸甲酯及其共聚物所组成的组中选择。有机聚合物最好是具有较高重均分子量的聚烯烃化合物。
对于具有较高分子量的聚烯烃化合物来说，最好使用重均分子量为一百万或更大的超高分子量聚乙烯(UHMWPE)或超高分子量聚丙烯(UHMWPP)。
此聚烯烃化合物还可由具有较高分子量的第一聚烯烃如聚乙烯和具有较低分子量的第二聚烯烃的混合物组成。第二聚烯烃可与第一聚烯烃相同或不同。
然而，也可以采用具有较高分子量的第一聚烯烃和具有较高分子量的第二聚烯烃的混合物，其中第二聚烯烃与第一聚烯烃不同，例如为UHMWPE和UHMWPP的混合物。这种混合物具有较高的耐高温性和具有较小的收缩率。
多种吸湿材料可用于本发明的吸湿板，例如硅胶粉或分子筛粉。吸湿材料最好包括固体化合物，其可化学地吸收湿气并且即使在吸湿后还能保持其固态。例如，对于这些吸湿材料的固体化合物来说，可采用碱金属氧化物化合物、碱土金属氧化物化合物、硫酸化合物、金属卤化物化合物、高氯酸盐化合物、有机化合物和沸石。优选的吸湿材料例如为氧化钙、氧化钡、氧化镁、钾、沸石硅铝酸钠(zelolite SodiumAlumino-Silicate)、硅胶或P2O5。
本发明还涉及一种制造吸湿板的方法。已经发现，当采用具有较高重均分子量的有机聚合物来粘合吸湿材料颗粒时，可以采用简单制造方法。即制造以上的吸湿板的方法，其中将吸湿物质的颗粒与有机聚合物颗粒混合在一起，之后在所述聚合物的玻璃转变温度以上的温度情况下对其进行轧制。或者将吸湿物质的颗粒与熔融的晶体或玻璃状有机聚合物混合在一起，并将其挤压成板，然后在比所述聚合物的熔点或玻璃转变温度更低的温度下对所述板进行拉伸。又或者将吸湿物质的颗粒混合在有机聚合物溶液中，然后在非溶剂中对所述溶液进行纺丝处理。
本发明还涉及一种容纳在一个密封容器内的有机电致发光器件，此容器设置在本发明的吸湿板的内部。美国专利US5124204(与图1相结合)介绍了一种传统的有机电致发光器件，其通过在玻璃基板2上按顺序地形成下透明电极3、下绝缘层4、电致发光层5、上绝缘层6和上电极7来制备。这些层3-7的结构称为EL元件1，其中应当注意的是在一些EL元件中，电致发光层5可取代下绝缘层4和/或上绝缘层6来用作绝缘层。为了防止湿气到达EL元件，在EL元件上覆盖了密封板12，其通过粘合剂9如环氧树脂粘附在玻璃基板2上。密封板12由防潮板13和吸湿板14构成。
为了得到非常可靠的有机电致发光器件，吸湿板应含有大量的吸湿材料，以便在有机电致发光器件的整个寿命期间能够吸收湿气。如上所述，现有技术的吸湿板的缺点在于，在实际中吸湿材料的含量增加会导致吸湿板的集成度下降，并使吸湿板易于形成裂纹和分解。由于这种分解，吸湿材料颗粒可能与EL元件相接触，这使得EL元件的性能下降。这样就为本发明的吸湿板带来了进一步的优点：根据本发明的吸湿板能够可靠地粘合和固定吸湿材料的所有颗粒。此优点对在有机电致发光器件中使用吸湿板尤其有利。
参考下述的实施例可以清楚和了解本发明的这些和其它方面。
附图说明
在附图中：
图1是包括有吸湿板的有机电致发光器件的截面图，和
图2是显示了根据本发明的吸湿板的截面图的电子显微图像。
这些附图只是说明性的，并且未按比例绘制。特别是为清晰起见，一些尺寸被放大了很多。
具体实施方式
图1显示了包括有玻璃衬底2的电致发光(EL)显示装置1，在衬底2上通过本领域已公知的工艺如物理或化学气相沉积或喷墨印刷而沉积了若干层。装置1包括有源或发射层3，其包括有机电致发光材料如香豆素(有机LED)或共轭聚合物如PPV(聚对亚苯基亚乙烯基)或PPV衍生物(聚合物LED)，它们夹在由导电材料制成的两层电极层图案之间。在此示例中，电极层包括直接沉积在玻璃衬底2上的列或数据电极4，以及行或选择电极5，从而形成了一个发光二极管(LED)的矩阵。至少电极4是由对有源层3所发出的光来说为透明的材料如铟锡氧化物(ITO)制成。在操作过程中，驱动列电极4以使其相对于行电极5具有足够高的正电压，从而在有源层3中注入空穴。
层3，4和5的叠层容纳在空腔8内，其由通过粘合剂6如热固性双组分环氧树脂固定在玻璃衬底2上的盖板7而形成。由玻璃衬底2和采用粘合剂6密封在玻璃衬底2上的盖板7所形成的密封容器的内部设有根据本发明的吸湿板9，使得吸湿材料与层3，4和5的叠层间隔开。例如，吸湿板9可如图1所示地与盖板7相连。
下面将通过几个示例来解释本发明，这些示例不应视为限制了本发明的范围。
在第一示例中，采用氧化钙作为吸湿材料。为了粘合大小从几个微米到几百微米的氧化钙颗粒，采用UHMW聚乙烯(UHMWPE)。UHMWPE的重均分子量大于106，可从Aldrich公司买到。板的材料通过将10克氧化钙和0.1克UHMWPE分散于10克奈烷溶剂中而生产出。在约160摄氏度下搅拌此悬浮液约10分钟，生产出溶液。将此溶液倒入盘中，让溶剂蒸发。或者，采用过量的二氯甲烷提取出奈烷。所得的干膜在室温下轧制到所需厚度，得到具有高孔隙率的自立式板。已经发现，当这些板暴露在相对湿度为80％的潮湿环境下时，所有氧化钙几乎立即发生反应，形成氢氧化钙。
在约100摄氏度下对这些板进行拉伸到例如为2的拉伸比，可以进一步地增大此孔隙率。
或者，可在非溶剂中对此溶液进行纺丝处理，从而得到根据本发明的吸湿板。
在第二示例中，采用带有较低玻璃转变湿度的聚合物粘合剂，例如颗粒大小约为1微米的聚四氟乙烯(PTFE，其重均分子量MW约为106)粉。PTFE粉分散在氧化钙颗粒中。在混合物中PTFE的浓度为8％重量。之后，在室温下轧制混合物以产生多孔的自立式薄膜。在混合和轧制过程中，PTFE形成母材，其中吸湿材料颗粒受到限制。当在室温下进行此工艺时，孔隙率总是能得以保持，然而与系统中增大的聚合物量相比其较小。
在第三示例中，在聚合物的熔融中将玻璃状的无规立聚苯乙烯(MW＝107)与吸湿材料颗粒如氧化钡混合在一起。在此混合物中聚苯乙烯的浓度为20％重量。之后，采用平模将熔融物挤压成薄膜。在冷却后正好在其玻璃转变温度之上、即约100摄氏度下对薄膜进行拉伸，从而生产出多孔的吸湿板。
在第四示例中，将10％的聚环氧乙烷(MW＝8×106)与吸湿材料如沸石硅铝酸钠(0.6K2O∶4Na2O∶Al2O3∶2SiO2∶xH2O)混合在一起。在系统中添加氯仿(80％)，以便溶解聚合物并帮助其与吸湿颗粒的良好混合。混合物可以是能制成具有优良吸湿性能的薄膜的溶液。
图2显示了根据本发明的吸湿板的横截面的电子显微图像。此图像显示了少量的有机聚合物如何与吸湿材料颗粒粘合在一起。
总之，本发明涉及一种含有少量具有较高重均分子量的有机聚合物和大量吸湿物质的颗粒的吸湿板。虽然吸湿材料的含量较高，然而根据本发明的吸湿板不容易形成裂纹和分解，还具有较高的孔隙率。由于这些特性，根据本发明的吸湿板对于在有机电致发光器件中的应用尤其有用。
应当理解，上述实施例和示例只是说明本发明而不是限制本发明，在不脱离所附权利要求的范围的前提下，本领域的技术人员可以设计出许多其它的实施例。
虽然根据本发明的吸湿板含有吸湿材料颗粒，然而这些颗粒可以是任何形状，例如粒状、薄片、伸长颗粒等。
在权利要求中，任何括号内的标号不应视为限制了权利要求。动词“包括”及其变形并不排除在权利要求中申明的元件或步骤以外的其它元件或步骤的存在。
Claims (10)
1.一种吸湿板，其包括有机聚合物和分散在所述有机聚合物中的吸湿材料颗粒，其特征在于，所述聚合物为重均分子量大于1百万的超高分子量聚合物。
2.根据权利要求1所述的吸湿板，其特征在于，所述吸湿板含有80到99.9％重量的吸湿材料颗粒和0.1到20.0％重量的超高分子量聚合物。
3.根据权利要求2所述的吸湿板，其特征在于，所述吸湿板含有95到99.9％重量的吸湿材料颗粒和0.1到5.0％重量的超高分子量聚合物。
4.根据权利要求1、2或3所述的吸湿板，其特征在于，所述超高分子量聚合物为线性聚合物。
5.根据权利要求1、2或3所述的吸湿板，其特征在于，所述聚合物为交联的。
6.根据权利要求1、2或3所述的吸湿板，其特征在于，所述聚合物从由聚乙烯、聚丙烯、聚苯乙烯、聚环氧乙烷、聚环氧丙烷、聚丙烯酸酯、聚碳酸酯、聚甲基丙烯酸甲酯及其共聚物所组成的组中选择。
7.一种制造根据权利要求1所述的吸湿板的方法，其特征在于，将吸湿物质的颗粒与有机聚合物颗粒混合在一起，之后在所述聚合物的玻璃转变温度以上的温度情况下对其进行轧制。
8.一种制造根据权利要求1所述的吸湿板的方法，其特征在于，将吸湿物质的颗粒与熔融的晶体或玻璃状有机聚合物混合在一起，并将其挤压成板，然后在比所述聚合物的熔点或玻璃转变温度更低的温度下对所述板进行拉伸。
9.一种制造根据权利要求1所述的吸湿板的方法，其特征在于，将吸湿物质的颗粒混合在有机聚合物溶液中，然后在非溶剂中对所述溶液进行纺丝处理。
10.一种有机电致发光器件(1)，包括：
衬底(2)，
电致发光元件，其包括夹在两层导电层(4，5)之间的至少一层有机材料的电致发光层(3)，所述电致发光层(3)在所述层承受电电时产生光，
湿气不可渗透层(7)，其与所述衬底(2)和粘合剂(6)一起将所述电致发光元件封住，和
根据权利要求1、2或3所述的吸湿板(9)，所述吸湿板(9)位于所述电致发光元件和所述湿气不可渗透层(7)之间。
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| DE60238402D1 (de) | 2011-01-05 |
| ATE489832T1 (de) | 2010-12-15 |
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| US6800350B2 (en) | 2004-10-05 |
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| CN1462568A (zh) | 2003-12-17 |
| JP2004526569A (ja) | 2004-09-02 |
| KR100869239B1 (ko) | 2008-11-18 |
| US20020172839A1 (en) | 2002-11-21 |
| EP1396175A1 (en) | 2004-03-10 |
| TW583891B (en) | 2004-04-11 |
| KR20030017629A (ko) | 2003-03-03 |
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