CN105246999B - 压敏粘合剂组合物、压敏粘合膜以及使用其制造有机电子装置的方法 - Google Patents
压敏粘合剂组合物、压敏粘合膜以及使用其制造有机电子装置的方法 Download PDFInfo
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- CN105246999B CN105246999B CN201480030234.9A CN201480030234A CN105246999B CN 105246999 B CN105246999 B CN 105246999B CN 201480030234 A CN201480030234 A CN 201480030234A CN 105246999 B CN105246999 B CN 105246999B
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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Abstract
本发明提供一种压敏粘合剂组合物、一种压敏粘合膜以及一种使用其制造有机电子装置的方法。所述压敏粘合剂组合物可以有效地防止来自外界环境的水分或氧气渗入有机电子装置,并且展现出在如高温高湿的恶劣环境下的可靠性以及优异的光学性能,还提供了一种包含所述压敏粘合剂组合物的压敏粘合膜。
Description
技术领域
本发明涉及一种压敏粘合剂组合物、一种压敏粘合膜以及一种使用其制造有机电子装置的方法。
背景技术
有机电子装置(OED)指的是包括利用空穴与电子产生电荷交替的有机材料层的装置,可以包括例如:光伏器件、整流器、发射器和有机发光二极管(OLED)。
OLED作为一种典型的OED,与传统光源相比,具有更低的能耗和更快的响应速度,还能形成更薄或更轻的显示器。另外,OLED由于其优异的空间利用率而有望应用于多种领域,包括各种便携式装置、监视器、笔记本电脑和电视机。
耐久性是扩展OLED的商品化和应用的一个主要问题。OLED中所包括的有机材料和金属电极非常容易被外界因素例如水分氧化,并且包括OLED的产品对于环境因素高度敏感。因此,已经提出多种方法以防止氧气或水分从外界环境渗入例如OLED的有机电子装置中。
在专利文件1中,提供了一种粘合剂封装组合物和一种有机电子发光装置,由于基于聚异丁烯(PIB)的压敏粘合剂而加工性能差且高温高湿条件下可靠性低。
相应地,对于有机电子装置,需要开发一种在高温高湿下能够保障所需的寿命、很好的防止水分的渗透、保持可靠性并且具有优异的光学特性的封装剂。
[现有技术文件]
[专利文件]
(专利文件1)韩国未审查专利No.2008-0088606
发明内容
技术问题
本发明旨在提供一种压敏粘合剂组合物,该压敏粘合剂组合物能够形成一种可以有效防止外界环境中的水分和氧气渗入有机电子装置并且具有例如可操作性和加工性能等优异的力学性能以及优异的透明性的结构,还提供了一种压敏粘合膜以及一种使用其制造有机电子装置的方法。
技术方案
一方面,本发明提供了一种压敏粘合剂组合物。所述压敏粘合剂组合物可以例如应用于有机电子装置如OLED的密封或封装。
这里用到的术语“有机电子装置”是指具有包括在一对彼此相对的电极之间利用空穴与电子产生电荷交替的有机材料层的结构的产品或装置,并且可以包括例如:光伏器件、整流器、发射器和有机发光二极管(OLED),但并不局限于此。在一个实例中,所述有机电子装置可以是OLED。
在本发明的一个示范性实施例方式中,所述压敏粘合剂组合物可以包含封装树脂,可以通过活化能射线辐射而聚合的多官能活化能射线-可聚合化合物,以及满足化学式1的硅烷化合物:
[化学式1]
在化学式1中,R1为氢或烷基。例如,R1可以是一个含有1-4个或1-2个碳原子的烷基。此外,在式1中,R2和R3各自独立地是氢或直链、支链或环状烷基,或者R2与R3连接而形成环状烷基。例如,R2和R3可以各自独立地是氢或直链、支链或环状烷基。此处,直链烷基可以含有1-10个、1-6个或者1-4个碳原子,支链烷基可以含有3-10个、3-6个或3-4个碳原子,环状烷基可以含有3-10个、3-8个、3-6个或3-4个碳原子。此外,R2可以与R3相连,从而形成含有2-10个、3-10个、4-9个或4-8个碳原子的环状烷基。此外,在化学式1中,R4、R5和R6各自独立地是氢、烷基或烷氧基,R4、R5和R6中的至少一个是烷氧基,n为1以上的整数。具体而言,R4、R5和R6各自独立地是含有1-10个、1-6个、1-4个或1-2个碳原子的烷基;或者含有1-10个、1-8个、1-4个或1-2个碳原子的烷氧基。此处,R4、R5和R6中的至少一个可以是烷氧基,并且R4、R5和R6可以全都是烷氧基,但是本发明并不局限于此。在一个实例中,对硅烷化合物没有特别的限制,只要它满足化学式1,例如,它可以是3-甲基丙烯酰氧基丙基三甲氧基硅烷、3-甲基丙烯酰氧基丙基三乙氧基硅烷、3-丙烯酰氧基丙基三甲氧基硅烷、3-丙烯酰氧基丙基三乙氧基硅烷、3-甲基丙烯酰氧基甲基三乙氧基硅烷、3-甲基丙烯酰氧基甲基三甲氧基硅烷、3-丙烯酰氧基丙基甲基二甲氧基甲基硅烷、甲基丙烯酰氧基甲基甲基二甲氧基硅烷、甲基丙烯酰氧基甲基甲基二乙氧基硅烷、甲基丙烯酰氧基丙基甲基二甲氧基硅烷、甲基丙烯酰氧基丙基甲基二乙氧基硅烷、甲基丙烯酰氧基丙基二甲基甲氧基硅烷或甲基丙烯酰氧基丙基二甲基乙氧基硅烷。硅烷化合物中的丙烯酰基可以通过与压敏粘合剂组合物中的封装树脂或活化能射线-可聚合化合物交联来增强界面压敏粘合强度。相对于100重量份的所述封装树脂,硅烷化合物的含量可以为例如0.1-10、0.5-8、0.8-5、1-5、1-4.5或1-4重量份。
在一个实例中,所述活化能射线-可聚合化合物可以与满足化学式1的硅烷化合物形成交联结构,而且这种交联结构可以与封装树脂形成半互穿聚合物网络(半-IPN)。也就是说,所述压敏粘合剂组合物可以包含半-IPN。术语“半-IPN”包含至少一种聚合物交联结构(聚合物网络)和至少一种直链或支链聚合物,并且至少一部分直链或支链聚合物具有穿入聚合物交联结构的结构。因为直链或支链聚合物在理论上可以从聚合物交联结构中分开而没有化学键损失,因此半-IPN可以与IPN结构区分开来。
在一个示范性实施方式中,交联结构可以是通过加热形成的交联结构,通过活化能射线辐射形成的交联结构,或通过在室温下老化形成的交联结构。这里,对于“活化能射线”的种类,可以包括微波、红外(IR)射线、紫外(UV)射线、X射线、γ射线以及例如α-粒子束、质子束、中子束或电子束的粒子束,并且通常可以包括UV射线和电子束。由于引入了这种半-IPN结构,可以提高压敏粘合剂组合物的力学性能例如加工性能,增强阻湿粘合性能,实现透明性,而且可以实现目前还未能达到的高防潮性能和优异的面板寿命。
在一个实例中,所述活化能射线-可聚合化合物可以与满足化学式1的硅烷化合物形成交联结构,而且封装树脂可与活化能射线-可聚合化合物或满足化学式1的硅烷化合物形成交联结构,由此形成互穿聚合物网络(IPN)结构。另外,术语“IPN结构”指的是至少两种交联结构存在于压敏粘合剂中的状态。在一个实例中,IPN结构指的是以交织、缠结或穿透的状态包含至少两种交联结构的结构。例如,本发明的组合物可以包含由封装树脂形成的交联结构(在下文中,被称为“第一交联结构”)和由活化能射线-可聚合化合物与满足化学式1的硅烷化合物反应形成的交联结构(在下文中,被称为“第二交联结构”),并且第一和第二交联结构可以处于交织状态或缠结状态。也就是说,由于压敏粘合剂组合物包含处于交联状态的半-IPN或IPN结构,所以通过提高压敏粘合剂的压敏粘合强度而在例如高温高湿的恶劣环境下实现压敏粘合剂的优异耐久性和可靠性,以及防止因水分渗入造成的界面压敏粘合强度减小。
在本发明的一个示例性实施方式中,所述封装树脂的玻璃化转变温度可以小于0℃、-10℃、-30℃、-50℃或-60℃。这里,玻璃化转变温度指的是经剂量为约1J/cm2以上的UV射线辐射后的玻璃化转变温度,或者是在UV辐射后又进行热固化之后的玻璃化转变温度。
在一个实例中,封装树脂可以包含苯乙烯类树脂或弹性体、聚烯烃类树脂或弹性体、其他弹性体、聚氧化烯类树脂或弹性体、聚酯类树脂或弹性体、聚氯乙烯类树脂或弹性体、聚碳酸酯类树脂或弹性体、聚苯硫醚类树脂或弹性体、聚酰胺类树脂或弹性体、丙烯酸酯类树脂或弹性体、环氧类树脂或弹性体、有机硅类树脂或弹性体、氟类树脂或弹性体、或者它们的混合物。
这里,苯乙烯类树脂或弹性体可以是例如苯乙烯-乙烯-丁二烯-苯乙烯(SEBS)嵌段共聚物、苯乙烯-异戊二烯-苯乙烯(SIS)嵌段共聚物、丙烯腈-丁二烯-苯乙烯(ABS)嵌段共聚物、丙烯腈-苯乙烯-丙烯酸酯(ASA)嵌段共聚物、苯乙烯-丁二烯-苯乙烯(SBS)嵌段共聚物、苯乙烯类同质共聚物或它们的混合物。烯烃类树脂或弹性体可以是例如高密度聚乙烯类树脂或弹性体、低密度聚乙烯类树脂或弹性、聚丙烯类树脂或弹性体、或它们的混合物。弹性体可以是例如酯类热塑弹性体、烯烃类弹性体、有机硅类弹性体、丙烯酸酯类弹性体或它们的混合物。其中,烯烃类热塑性弹性体可以是聚丁二烯树脂或弹性体或者聚异丁烯树脂或弹性体。聚氧化烯类树脂或弹性体可以是例如聚甲醛类树脂或弹性体、聚氧化乙烯类树脂或弹性体、或它们的混合物。聚酯类树脂或弹性体可以是例如聚对苯二甲酸乙二醇酯类树脂或弹性体、聚对苯二甲酸丁二醇酯类树脂或弹性体、或者它们的混合物。聚氯乙烯类树脂或弹性体可以是聚偏二氯乙烯。封装树脂可以包含碳氢化合物例如,三十六烷或石蜡的混合树脂。聚酰胺类树脂或高弹体可以是例如尼龙。丙烯酸酯类树脂或高弹体可以是聚(甲基)丙烯酸丁酯。环氧类树脂或弹性体可以是例如双酚型如双酚A型、双酚F型、双酚S型和它们的氢化产物;酚醛树脂型如苯酚酚醛型或甲酚酚醛型;含氮环形如三缩水甘油基异氰尿酸酯型或乙内酰脲型;脂环族型;脂肪族型;芳香族型如萘型或联苯型;缩水甘油基型如缩水甘油醚型、缩水甘油胺型或缩水甘油酯型;双环形如二环戊二烯型;酯型;醚酯型;或它们的混合物。有机硅类树脂或弹性体可以是例如聚二甲基硅氧烷。此外,氟类树脂或弹性体可以是聚三氟乙烯树脂或弹性体、聚四氟乙烯树脂或弹性体、聚三氟氯乙烯树脂或弹性体、聚六氟丙烯树脂或弹性体、聚偏二氟乙烯、聚氟乙烯、聚乙烯丙烯氟化物,或它们的混合物。
上文所列出的树脂或弹性体中的一种可以接枝到例如马来酸酐上,与所列出的另一种树脂或弹性体或用于制备树脂或弹性体的单体共聚,或用不同于上述用到的树脂或弹性体的化合物改性。所述化合物可以是羧基封端的丁二烯-丙烯腈共聚物。
在一个实例中,所述压敏粘合剂组合物是封装树脂,其可以包括上文描述类型的烯烃类弹性体、有机硅类弹性体或丙烯酸酯类弹性体,但本发明并不局限于此。
特别地,所述封装树脂可以是二烯和具有一个碳碳双键的烯烃类化合物的共聚物。这里烯烃类化合物可以包含异丁烯、丙烯或者乙烯,二烯可以是能与烯烃类化合物聚合的单体,例如1-丁烯、2-丁烯、异戊二烯或丁二烯。也就是说,本发明的封装树脂可以是,例如异丁烯单体的均聚物;异丁烯单体和能与其聚合的单体共聚制备的共聚物;或它们的混合物。在一个实例中,具有一个碳碳双键的烯烃类化合物与二烯的共聚物可以是丁基橡胶。当使用如上所述的特定树脂时,在本发明中将会获得的的阻湿性会令人满意。另外,由于传统的异丁烯聚合物具有低透湿性和低耐热性,本发明通过引入如上文描述的多种交联系统可以提高防潮性和耐热性。
在所述压敏粘合剂组合物中,树脂或弹性体成分具有使压敏粘合剂组合物能够被塑化成膜型的重均分子量(Mw)。例如,树脂或弹性体的重均分子量(Mw)可以约为100,000-2,000,000、100,000-1,500,000或者100,000-1,000,000。这里所用到的术语“重均分子量”指的是由凝胶渗透色谱法(GPC)测得的相对于标准聚苯乙烯的转换值。然而,树脂或弹性体成分并不一定具有上面所提到的重均分子量。例如,当树脂或弹性体成分的分子量并不足以形成薄膜时,可将另外的粘合剂树脂混入压敏粘合剂组合物中。
根据上文的描述,本发明中的压敏粘合剂组合物可以包含与封装树脂有高相容性并能与封装树脂形成特定交联结构的活化能射线-可聚合化合物。
例如,本发明的压敏粘合剂组合物可以包含通过活化能射线辐射能与封装树脂聚合的多官能活化能射线-可聚合化合物。所述活化能射线-可聚合化合物可以指例如包含至少两个通过活化能射线辐射可以参与聚合反应的官能团的化合物,例如,包含像乙烯一样的不饱和双键的官能团(如丙烯酰基或甲基丙基酰基),和如环氧基或氧杂环丁烷基的官能团。
可以使用例如多官能丙烯酸酯(MFA)来作为上述的多官能活化能射线-可聚合化合物。
另外,所述可以通过活化能射线辐射来聚合的多官能活化能射线-可聚合化合物可满足化学式2。另外,相对于100重量份的所述封装树脂,活化能射线-可聚合化合物的含量可以为5-30、5-25、8-20、10-18或12-18重量份。
[化学式2]
在化学式2中,R1是氢或含有1-4个碳原子的烷基,n为2以上的整数,X是由含有3-30个碳原子的直链、支链或环状烷基产生的残基,此时,当X是环状烷基产生的基团时,X可以是由含有3-30个、6-28个、8-22个或12-20个碳原子的环烷基产生的基团。此外,当X是由直链烷基产生的残基时,X可以是含有3-30个、6-25个或8-20个碳原子的直链烷基产生的残基。此外,当X是由支链烷基产生的残基时,X可以是由含有3-30个、5-25个或6-20个碳原子的支链烷基产生的残基。
此处使用的术语“由烷基产生的残基”是指由烷基组成的特定化合物的残基。在一个实例中,在化学式2中,当n等于2时,X可以是亚烷基。此外,当n为3以上时,烷基中的至少两个氢原子可以从X释出,然后与化学式2中的(甲基)丙烯酰基相连。
除非另外特别限定,此处使用的术语“烷基”可以指含有1-30个、1-25个、1-20个、1-16个、1-12个、1-8个或1-4个碳原子的烷基。所述烷基可以具有直链、支链或环状结构,也可以可选择的被至少一个取代基取代。
除非另外特别限定,此处使用的术语“亚烷基”可以指含有2-30个、2-25个、2-20个、2-16个、2-12个、2-10个或2-8个碳原子的亚烷基。所述亚烷基可以具有直链、支链或环状结构,也可以可选择的被至少一个取代基取代。
除非另外特别限定,此处使用的术语“烷氧基”可以指含有1-20个、1-16个、1-12个、1-8个或1-4个碳原子的烷氧基。所述烷氧基可以具有直链、支链或环状。此外,所述烷氧基也可以可选择的被至少一个取代基取代。
这种可以通过活化能射线照射聚合的多官能活化能射线-可聚合化合物可以是任何一种满足化学式2的物质而没有限制。例如,这种化合物可以是1,4-丁二醇二(甲基)丙烯酸酯、1,3-丁二醇二(甲基)丙烯酸酯、1,6-己二醇二(甲基)丙烯酸酯、1,8-辛二醇二(甲基)丙烯酸酯、1,12-十二烷二醇二(甲基)丙烯酸酯、新戊二醇二(甲基)丙烯酸酯、二环戊基二(甲基)丙烯酸酯、环己烷-1,4-二甲醇二(甲基)丙烯酸酯、三环癸烷二甲醇(甲基)二丙烯酸酯、二羟甲基二环戊烷二(甲基)丙烯酸酯、新戊二醇改性的三甲基丙烷二(甲基)丙烯酸酯、金刚烷二(甲基)丙烯酸酯、三甲基丙烷三(甲基)丙烯酸酯、或它们的混合物。
例如,可以使用分子量少于1,000并包含至少两个官能团的化合物作为多官能活化能射线-可聚合化合物。在这种情况下,所述分子量可以指重均分子量或者传统的分子质量。多官能活化能射线-可聚合化合物中的环状结构可以是碳环结构、杂环结构、单环结构以及多环结构的任意一种。
在本发明的一个示范性实施方式中,压敏粘合剂组合物可以进一步地包含可以引发上述多官能活化能射线-可聚合化合物的聚合反应的自由基引发剂。自由基引发剂可以是光引发剂或热引发剂。可能通过考虑固化速率和黄化可能性来适当的选择具体类型的光引发剂。例如,作为光引发剂,可以使用安息香类、羟基酮类、氨基酮类或氧化膦类光引发剂,具体地为,安息香、安息香甲醚、安息香乙醚、安息香异丙醚、安息香正丁醚、安息香异丁醚、苯乙酮、二甲氨基苯乙酮、2,2-二甲氧基-2-苯基苯乙酮、2,2-二乙氧基-2-苯基苯乙酮、2-羟基-2-甲基-1-苯基丙-1-酮、1-羟基环己基苯甲酮、2-甲基-1-[4-(甲硫基)苯基]-2-吗啉基-丙-1-酮、4-(2-羟基乙氧基)苯基-2-(羟基-2-丙基)酮、二苯甲酮、对苯基二苯甲酮、4,4'-二乙基氨基二苯甲酮、二氯二苯甲酮、2-甲基蒽醌、2-乙基蒽醌、2-叔丁基蒽醌、2-氨基蒽醌、2-甲基噻吨酮、2-乙基噻吨酮、2-氯噻吨酮、2,4-二甲基噻吨酮、2,4-二乙基噻吨酮、苄基二甲基缩酮(benzyldimethylketal)、苯乙酮二甲基缩酮(acetophenonedimethylketal)、对二甲氨基苯甲酸酯、低聚[2-羟基-2-甲基-1-[4-(1-甲基乙烯基)苯基]丙酮]或2,4,6-三甲基苯甲酰基-二苯基-氧化膦。
相对于100重量份的所述活化能射线-可聚合化合物,自由基引发剂的重含量可以为0.2-20、0.5-18、1-15或2-13重量份。由此,可以有效地诱导活化能射线-可聚合化合物发生反应,并可以阻止由固化后的残留成分造成的压敏粘合剂组合物的物理性能的退化。
在一个实例中,所述压敏粘合剂组合物可以更进一步地包含增粘剂。这种增粘剂可以是一种氢化环状烯烃类聚合物。例如,将石油树脂氢化获得的氢化石油树脂可以用作增粘剂。所述氢化石油树脂可以是部分或者完全地被氢化,也可以是这些树脂的混合物。这种增粘剂与压敏粘合剂组合物具有很好的相容性和优异的阻湿性,还含有少量的有机的挥发性成分。氢化石油树脂的具体例子可以是氢化萜烯类树脂、氢化酯类树脂或氢化二环戊二烯类树脂。所述增粘剂的重均分子量可以为约200到5,000。增粘剂的含量是可以根据需要适当控制的。例如,增粘剂的含量可以根据压敏粘合剂组合物的交联程度来考虑。根据一个实例,相对于100重量份的所述压敏粘合剂组合物中固体含量,增粘剂的含量可以为5-100,8-95,10-93或15-90重量份。
当有需要时,所述压敏粘合剂组合物可以更进一步地包含吸湿剂。术语“吸湿剂”可以指通过化学反应来去除渗入到下文中将要说明的压敏粘合膜中的水分和水蒸气的材料。当本发明中的压敏粘合剂组合物包含吸湿剂时,下文将描述的透光率可能达不到形成薄膜的要求,但是却能获得优异的阻湿性。具体地,所述压敏粘合剂组合物可以形成用于封装有机电子装置的薄膜。在此情况下,当压敏粘合剂组合物不包含吸湿剂并且展现出优异的透明性时,可以被应用于顶发射有机电子装置的封装,而当压敏粘合剂组合物包含吸湿剂并展现优异的阻湿性时,可以被应用于底发射有机电子装置的封装。然而,本发明并不局限于此。也就是说,当所述压敏粘合剂组合物不包含吸湿剂并且展现良好的透明性时,也可以被用于底发射有机电子装置的封装。
例如,所述吸湿剂可以被均匀地分散在压敏粘合剂组合物或下文将要描述的压敏粘合层中。这里,所述的均匀分散的状态可以指吸湿剂以相同或实质上相同的密度存在于压敏粘合剂组合物或压敏粘合层的任何部分的状态。作为这里所使用的吸湿剂,例如可以使用金属氧化物、硫酸盐或有机金属氧化物。具体地,硫酸盐可以是硫酸镁、硫酸钠或硫酸镍,有机金属氧化物可以是氧化铝辛酸盐(aluminum oxide octylate)。这里,所述金属氧化物可以是五氧化二磷(P2O5)、氧化锂(Li2O)、氧化钠(Na2O)、氧化钡(BaO)、氧化钙(CaO)或氧化镁(MgO),并且所述金属盐的实例可以为硫酸盐,例如硫酸锂(Li2SO4)、硫酸钠(Na2SO4)、硫酸钙(CaSO4)、硫酸镁(MgSO4)、硫酸钴(CoSO4)、硫酸镓(Ga2(SO4)3)、硫酸锑(Ti(SO4)2)或硫酸镍(NiSO4);金属卤化物,例如氯化钙(CaCl2)、氯化镁(MgCl2)、氯化锶(SrCl2)、氯化钇(YCl3)、氯化铜(CuCl2)、氟化铯(CsF)、氟化钽(TaF5)、氟化铌(NbF5)、溴化锂(LiBr)、溴化钙(CaBr2)、溴化铯(CeBr3)、溴化锡(SeBr4)、溴化钒(VBr3)、溴化镁(MgBr2)、碘化钡(BaI2)或碘化镁(MgI2);或金属氯酸盐,例如高氯酸钡(Ba(ClO4)2)或高氯酸镁(Mg(ClO4)2),但本发明并不局限于此。可以使用上面描述中的一种或至少两种材料来作为所述压敏粘合剂组合物中包含的吸湿剂。在一个实例中,当使用上述的至少两种材料时,吸湿剂可以是煅烧白云石。
这样的吸湿剂可以根据其用途控制适当的尺寸。在一个实例中,所述吸湿剂的平均直径可以控制到大约10-15000nm。具有以上平均直径的吸湿剂由于与水分的反应速度不会太高而易于存储,并且能有效地去除水分而对被封装的元件没有损害。
考虑到理想的屏障特性,可以适当地选择吸湿剂的含量而没有特殊限制。
当有需要时,所述压敏粘合剂组合物可以更进一步地包含水分阻滞剂。这里所使用的术语“水分阻滞剂”可以指能够阻止或防止水分或水蒸汽迁移进入薄膜而与水分没有或者有很低的反应活性的材料。粘土、滑石、针状硅石、平面硅石、多孔硅石、沸石、二氧化钛以及氧化锆中的一种或至少两种可以用作水分阻滞剂。另外,可以用有机改性剂处理水分阻滞剂的表面以促进有机材料的渗入。二甲基苄基氢化的牛脂季铵盐、二甲基氢化的油脂季铵盐、甲基油脂双-2-羟乙基季铵盐、二甲基脱氢化油脂季铵盐或者它们的混合物可以作为这种有机改性剂使用。
考虑到理想的阻滞特性,可以适当地选择水分阻滞剂的含量而没有特殊限制。
除了上文所描述的成分之外,还可以根据用途和下文将要说明的压敏粘合膜的制造方法来选择压敏粘合剂组合物中可以包含的各种添加剂。例如,所述压敏粘合剂组合物可以根据所需的物理性能包含适当范围含量的固化材料、交联剂或填料。
在一个实例中,本发明中的压敏粘合剂组合物可以具有50%以上的由式2所表示的凝胶含量。
[式2]
凝胶含量(wt%)=B/A×100
在式2中,A是压敏粘合剂组合物的质量,B是压敏粘合剂组合物在60℃下浸于甲苯中24小时再经200-目过滤器(孔径为200μm)过滤之后剩余的不溶物的干质量。
由式2表示的凝胶含量可以是50-99%、50-90%、50-80%或50-70%。也就是说,在本发明中,具有优异的水分阻滞性、可靠性和光学性能的压敏粘合剂组合物可以通过由凝胶含量确定合适范围的压敏粘合剂组合物的交联结构和交联度来获得。
另一方面,本发明提供了一种压敏粘合膜。所述压敏粘合膜可以包含压敏粘合层。另外,当储存在25℃且相对湿度50%下1小时的压敏粘合层对衬底的剥离强度(剥离速率:5mm/sec,剥离角度:180度)为P gf/25mm时,以及当储存在85℃且相对湿度85%下1小时的压敏粘合层对衬底的剥离强度(剥离速率:5mm/sec,剥离角度:180度)为Q gf/25mm时,所述压敏粘合膜可以满足式2。所述温度和湿度条件可以为恒温恒湿。
[式1]
Q≥1.3P
另外,在本发明的一个示例性实施方式中,在实现交联结构前或后,所述压敏粘合膜在25℃且相对湿度为50%下储存1小时后对于玻璃衬底的剥离强度(剥离速率:5mm/sec,剥离角度:180度)可以为1,000gf/inch以上。所述剥离强度是根据ASTM3330使用物性分析仪测量的。当压敏粘合剂组合物的组成或交联条件控制成具备这样的剥离强度时,可以提供一种能够实现对于电子装置的优异耐久性的密封或封装结构的压敏粘合膜。
所述压敏粘合膜的压敏粘合层可以进一步地含有上述压敏粘合剂组合物或者它的交联产物。压敏粘合层也可以具有膜或者薄片的形状。这种压敏粘合层可以用于封装有机电子元件。
在本发明的一个示例性实施方式中,所述压敏粘合层可以以上述的单层结构形成,或者由下文将要描述的至少两层形成。例如,所述压敏粘合层可以包含含有上述压敏粘合剂组合物或它的交联产物的第一层以及包含压敏粘合剂树脂或粘合剂树脂的第二层。包含在第二层中的压敏粘合剂树脂或粘合剂树脂可以与上文描述的封装树脂相同或不同,也可以由普通技术人员根据目的适当地选择。当压敏粘合层由至少两层形成时,上述压敏粘合强度或剥离强度可以对应于第一层或者第二层。另外,第一和第二层可包含也可以不包含吸湿剂。
在一个实例中,包含在第二层中的压敏粘合剂树脂可以包含含有至少一种热可固化官能团(如缩水甘油基、异氰酸酯基、羟基、羧基或酰胺基),或者含有至少一种电磁波可固化官能团(如环氧基、环醚基、硫醚基、乙缩醛基或内酯基)的可固化树脂,其可经过固化来展现优异的粘合性能。另外,这种树脂的特定类型可以是丙烯酸树脂、聚酯树脂、异氰酸酯树脂或环氧树脂,但并不局限于此。
在本发明中,芳香族或脂肪族、直链或支链环氧树脂都可以用作所述的可固化树脂。在本发明的一个示例性实施方式中,可以使用至少含有两种官能团且具有180到1,000g/eq的环氧当量的环氧树脂。当使用具有上述范围的环氧当量的环氧树脂时,固化产物的如粘合性能和玻璃化转变温度等特性会得到有效地维持。这样的环氧树脂可以是甲酚醛环氧树脂、双酚A型环氧树脂、双酚A型酚醛环氧树脂、苯酚酚醛环氧树脂、四官能环氧树脂、联苯型环氧树脂、三酚基甲烷型环氧树脂、烷基改性的三酚基甲烷酚醛树脂、萘型环氧树脂、二环戊二烯型环氧树脂以及二环戊二烯改性的苯酚型环氧树脂中的一种或至少两种的混合物。
在本发明的一个示例性实施方式中,所述第二层除了上述的树脂以外还可以包含与第一层相同或不同的其他成分,例如上文描述的活化能射线-可聚合化合物、自由基引发剂、增粘剂、吸湿剂、水分阻滞剂、分散剂或硅烷化合物。另外,所述第二层根据所需的物理性能还可以包含适当范围含量的可固化材料、固化剂或者填料。
对层叠第一层与第二层的顺序没有特别限制,因此第二层可以在第一层上形成,或第一层也可以在第二层上形成。
在一个实例中,所述压敏粘合膜可以在压敏粘合层的一个表面上包括阻隔膜。这种阻隔膜可以由本领域内通常使用的任何材料形成而没有限制。例如,这里,阻隔膜可以包含基层、有机底涂层、无机沉积层以及有机上涂层,并且有机上涂层可与压敏粘合层接触。
当制备成厚度为10μm的膜时,压敏粘合膜在100℉和相对湿度100%下对于膜的厚度方向上测得的水蒸气透过率(WVTR)为50、40、30、20、10g/m2·day或更少。通过控制包含压敏粘合剂组合物的压敏粘合层的组成或交联条件使得其具有如上所述的WVTR,可以实现当应用于有机电子装置的密封或封装结构时能够通过有效阻挡由外部环境渗透的水分或氧气来稳定地保护元件的密封或封装结构。WVTR越低时水分阻滞性能越好,因此WNTR的下限可以为但不特别限于0g/m2·day。
另外,所述压敏粘合膜在可见光区域具有很好的透光率。在一个实例中,本发明中的压敏粘合膜在可见光区域的透光率可以为85%以上。例如,所述压敏粘合膜在可见光区域的透光率可以为85%、87%、或90%或更高。另外,本发明中的压敏粘合膜除了具有优异的透光率还具有较低的雾度,在一个实例中,所述的压敏粘合膜可以具有3%、2%、1%、0.8%、0.5%或0.3%或更低的雾度。也就是说,本发明的压敏粘合剂组合物通过引入特定的交联体系可以在高温高湿下获得优异的光学性能以及可靠性。
所述压敏粘合膜可以进一步地包括基膜或者离型膜(在下文中,称作“第一薄膜”),压敏粘合层可以在基膜或离型膜上形成。所述结构还可以进一步包括形成在压敏粘合层上的基膜或离型膜(在下文中,称作“第二薄膜”)。
图1和2是示例性压敏粘合膜的横截面视图。
如图1所示,压敏粘合膜1可以包括形成在基膜或离型膜12上的压敏粘合层11。如图2所示,另一个示例性压敏粘合膜2可以进一步包括形成在压敏粘合层11上的基膜或离型膜21。虽然并未在图1、2中显示出来,但所述压敏粘合膜还可以具有压敏粘合剂组合物而没有例如基膜或离型膜的支撑衬底,因此具有只包括在室温下形成保持固相或半固相的薄膜或薄片的压敏粘合层的结构,或者在基膜和离型膜的两个表面都形成压敏粘合层的结构。
对第一薄膜的具体类型没有特别地限定。例如,塑料薄膜可以用作第一薄膜。所述第一薄膜可以是聚对苯二甲酸乙二醇酯薄膜、聚四氟乙烯薄膜、聚乙烯薄膜、聚丙烯薄膜、聚丁烯薄膜、聚丁二烯薄膜、氯乙烯共聚物薄膜、聚氨酯薄膜、乙烯-醋酸乙烯酯薄膜、乙烯-丙烯共聚物薄膜、乙烯-丙烯酸乙酯共聚物薄膜、乙烯-丙烯酸甲酯共聚物膜或聚酰亚胺薄膜。
当第一薄膜为离型膜时,可以对这种塑料薄膜的一个或两个表面施以适当的防粘处理。可以使用醇酸类防粘剂、有机硅类防粘剂、氟类防粘剂、氟化酯类防粘剂、聚烯烃类防粘剂或蜡类防粘剂来作为防粘处理中所用的防粘剂。考虑到耐热性,在这些防粘剂中,醇酸类防粘剂、有机硅类防粘剂及氟类防粘剂是常规使用的,但本发明并不局限于此。
基底的上表面或侧表面形成有阻气层的塑料薄膜可以用作第一薄膜。例如,这种薄膜可以直接构成有机电子装置的衬底以获得挠性元件。
对第二薄膜的种类也没有特殊限制。例如,作为第二薄膜,可以使用上述第一薄膜的范围内的与第一薄膜相同或不同的一种。
对第一或第二薄膜的厚度没有特别限制。在一个实例中,第一薄膜的厚度可以为约50-500μm或100-200μm。在这样的范围内,制造或制备压敏粘合剂或者有机电子装置的方法可以有效地自动化,而且还可以获得经济可行性的有益效果。
对第二薄膜的厚度也没有特别限制。例如,第一薄膜的厚度可以与第一薄膜相同或者相对更小或更大。
所述压敏粘合膜的压敏粘合层包括所述压敏粘合剂组合物,并且形成为薄膜或者薄片。在压敏粘合层中,压敏粘合剂组合物可以处于交联或者未交联的状态。压敏粘合层在室温下可以是固相或半固相。这种压敏粘合剂树脂可以在有机电子装置的封装结构中形成交联结构,这将会在下文中说明。
对压敏粘合层的厚度没有特别限制,但可以根据其应用来进行适当选择。例如,压敏粘合层的厚度可以为约5-200μm。压敏粘合层的厚度可以根据例如被用作有机电子装置的封装剂时的嵌入性(embeddability)及加工性能或经济可行性来控制。
另一方面,本发明提供了一种制造压敏粘合膜的方法。示范性的压敏粘合膜可以通过将压敏粘合剂组合物塑化为薄膜或薄片来制得。
在一个实例中,所述方法可以包括将含有压敏粘合剂组合物的涂层溶液涂布于薄膜或薄片状的基膜或离型膜上,然后将所涂布的涂层溶液干燥。所述方法还可以进一步包括在干燥的涂层溶液上粘附另外的的基膜或离型膜。
含有压敏粘合剂组合物的涂层溶液可以通过,例如将上述的压敏粘合剂组合物的各成飞溶解或分散于适合的溶剂中来制备。在一个实例中,当有需要时,可以将吸湿剂、阻滞剂或填料溶解或分散于溶剂中,研磨得到的产物,并将吸湿剂、阻滞剂或填料与封装树脂混合来制备压敏粘合剂组合物。
在涂层溶液的制备中所使用的溶剂的类型并未做特殊限制。但是,当干燥溶剂的时间太长或者需要高温干燥溶剂时,压敏粘合膜的加工性和耐久性会存在一些问题。由于这个原因,可以使用挥发温度为150℃以下的溶剂。考虑到薄膜的可塑性,可以将少量具有上述范围或更高的挥发温度的溶剂混合使用。所述溶剂可以是甲基乙基酮(MEK)、丙酮、甲苯、二甲基甲酰胺(DMF)、甲基溶纤剂(MCS)、四氢呋喃(THF)、二甲苯以及N-甲基吡咯烷酮(NMP)中的一种或至少两种,但并不局限于此。
将涂层溶液涂布于基膜或离型膜上的方法可以是例如刮涂法、辊式涂布法、喷涂法、凹版涂布法、幕涂法、缺角轮涂布法(comma coating)或唇涂布法的已知的涂布方法,但并不局限于此。
可以对所涂布的涂层溶液进行干燥来挥发溶剂,从而形成压敏粘合层。所述烘干可以在例如70-150℃下进行1-10分钟。干燥条件可以根据所使用的溶剂类型而变化。
干燥之后,可以在压敏粘合层上形成另外的基膜或离型膜。
另一个方面,本发明提供了一种用于封装有机电子装置的产品。这种用于封装有机电子装置的产品可以包括衬底;在衬底上形成的有机电子元件;以及封装有机电子元件的整个表面,例如上表面和侧表面的压敏粘合膜。所述压敏粘合膜可以包括含有处于交联状态的压敏粘合剂组合物的压敏粘合层。这种用于封装有机电子装置的产品可以更进一步地包括在压敏粘合层上表面形成的覆盖衬底。
这里,所述有机电子元件可以是例如有机发光元件。
另一个方面,本发明提供了一种制造有机电子装置的方法。例如,用于封装有机电子装置的产品可以是用所述压敏粘合膜制造的。
所述压敏粘合层可以形成一种能够在有机电子装置中展现优异的阻湿性能和光学性能、并能有效地固定和支撑衬底和覆盖衬底的结构的封装层。
另外,所述压敏粘合层可以不管在什么类型的有机电子装置(例如顶发射或底发射有机电子装置)中都能展现优异的透明性并且很稳定。
这里所使用的术语“封装层”可以指覆盖在有机电子装置的上表面和侧表面上的压敏粘合层。
图3是示例性有机电子装置的示意图,其中有机电子元件为有机发光元件。
例如,制造有机电子装置的方法可以包括将上述压敏粘合膜施用在上面形成有有机电子元件的衬底上以覆盖有机电子元件;然后固化所述压敏粘合膜。
这里所使用的术语“固化”可以指通过加热或UV辐射来形成本发明中具有交联结构的压敏粘合剂组合物从而制备压敏粘合剂。
具体地,有机电子元件32可通过以下方法形成:以例如真空沉积或溅射的方法在作为衬底的玻璃膜或聚合物膜31上形成透明电极,然后在透明电极上形成由例如空穴传输层、发光层和电子传输层组成的发光有机材料层,在其上进一步形成电极层。接着,设置压敏粘合膜的压敏粘合层以覆盖历经上述程序的衬底31的有机电子元件32的整个表面。
随后,利用层合机在加热以提供流动性的同时将压敏粘合层压合在有机电子元件上,并使压敏粘合层中的树脂交联,从而形成封装层。
在一个实例中,用于覆盖有机电子元件32的整个表面的压敏粘合层33可以先被转移到覆盖衬底34例如玻璃或聚合物膜。压敏粘合层转移到覆盖衬底34可以如下进行:在将第一或第二薄膜从粘合膜上剥离并使压敏粘合层与覆盖衬底34接触后,使用真空压制或真空层合机同时加热。在此过程中当压敏粘合剂包含可固化压敏粘合剂树脂并且固化反应过度进行时,封装层的内聚强度或压敏粘合强度有可能下降。因此,可以将加工温度控制在约100℃以下,将加工时间控制在5分钟之内。
封装层可以通过将转移有压敏粘合层的覆盖衬底34设置于有机电子元件32上,并进行热压过程来形成。
封装层可以通过固化压敏粘合层33来形成。固化工艺可以例如根据固化可固化压敏粘合剂树脂的方法在合适的加热室或UV室中进行。加热条件或者活化能射线的辐射条件可以根据有机电子元件的稳定性以及压敏粘合剂树脂的可固化性作出合适的选择,从而提高压制效率,并且可以进行应用热和压力的热压。
这里,描述了一个制造有机电子装置的方法的实例,但有机电子装置可以使用不同的方法来制造。例如,装置的制造是按照上文描述的方法来实施的,但是工艺的顺序或条件是可以改变的。例如,可以通过先将压敏粘合层转移到衬底31上的有机电子元件上而不是覆盖衬底34上,然后在层合覆盖衬底34后实施固化工艺来形成封装层。
有益效果
本发明可提供一种可以有效地防止来自外界环境的水分或氧气渗入有机电子装置中、并且在如高温高湿的恶劣环境下展现出良好的可靠性以及优异的光学性能的压敏粘合剂组合物,以及一种包含该压敏粘合剂组合物的压敏粘合膜。
附图说明
图1是和2是根据本发明的示例性实施方案的压敏粘合膜的横截面视图;以及
图3是根据本发明的一个示例性实施方案的用于封装有机电子装置的产品的横截面视图。
[附图标记说明]
1,2:压敏粘合膜
11:压敏粘合层
12:第一薄膜
21:第二薄膜
3:有机电子装置
31:衬底
32:有机电子元件
33:压敏粘合层或封装层
34:覆盖衬底
具体实施方式
在下文中,将参照实施例及对比实施例详细地描述本发明,但是本发明的范围并不局限于以下的实施例。
实施例1
添加90g作为封装树脂的丁基橡胶(Br268,EXXON)、10g作为增粘剂的氢化DCPD类增粘剂(SU-90,Kolon)、15g作为活化能射线-可聚合化合物的三环癸烷二甲醇二丙烯酸酯(M262,Miwon)、3g作为硅烷化合物的3-甲基丙烯酰氧基丙基三甲氧基硅烷(SigmaAldrich)和0.5g作为自由基引发剂的2,2-二甲氧基-1,2-二苯基乙-1-酮(Irgacure651,Ciba)的,在甲苯中稀释上述混合物以制备含固量约为20wt%的涂层溶液。
将制备好的溶液涂布在离型PET的离型表面上,再置于100℃的烘箱中干燥15分钟,由此制得包含厚度为20μm的压敏粘合层的压敏粘合膜。所制备的膜以2J/cm2辐照紫外射线后测量样品的物理性能。
实施例2
除了使用10g 3-甲基丙烯酰氧基丙基三甲氧基硅烷(Sigma Aldrich)之外,以实施例1所述的同样的方法制备压敏粘合膜。
对比实施例1
除了不使用3-甲基丙烯酰氧基丙基三甲氧基硅烷(0g)之外,以实施例1所述的同样的方法制备压敏粘合膜。
对比实施例2
除了用90g丙烯酸丁酯和10g丙烯酸代替实施例1中使用的丁基橡胶和氢化DCPD-类增粘剂之外,以实施例1所述的同样的方法制备压敏粘合膜。
在下文中,利用以下方法评价实施例与对比实施例的物理性能。
1.压敏粘合强度的测量
将实施例或对比实施例中制得的压敏粘合膜的宽度设置为1英寸,并将膜在25℃及相对湿度50%下保持1小时,然后测量压敏粘合膜的压敏粘合层对于OLED面板(无机沉积有氮化硅的玻璃)的剥离强度(玻璃速率:5mm/sec,剥离角度:180度)。
将实施例与对比实施例中制得的压敏粘合膜的宽度设置为1英寸,并将膜在85℃及相对湿度85%下保持1小时,然后测量压敏粘合膜的压敏粘合层对于OLED面板(无机沉积有氮化硅的玻璃)的剥离强度(玻璃速率:5mm/sec,剥离角度:180度)。
测量是在恒温恒湿条件下进行的,而且剥离强度是根据ASTM3330以物性分析仪测量的。
2.水蒸气透过率(WVTR)
通过将实施例和对比实施例所使用的树脂溶解在溶剂中以制备树脂组合物。将该树脂组合物施用于厚度为38μm的基膜(离型聚酯膜RS-21G,SKC)。随后,将所述组合物在110℃下干燥10分钟,由此形成具有100μm厚度的薄膜型层。然后,使薄膜型层保持在100°华氏温度和相对湿度100%下,所述基膜被剥离开,再从厚度方向测试薄膜型层的水蒸气透过率。水蒸气透过率是按照ASTM F1249来测量的。
3.雾度的测量
按照JIS K7105标准测试方法以雾度仪来测量如上所述制备的压敏粘合膜的雾度。
4.离型剥离强度的测量
将实施例与对比实施例中制得的压敏粘合膜的宽度设置为1英寸,并将膜在25℃及相对湿度50%下保持1周,然后测量对离型PET的压敏粘合膜的剥离强度(剥离速率:5mm/sec,剥离角度:180度)。
测量是在恒温恒湿条件下进行的,而且剥离强度是根据ASTM3330以物性分析仪测量的。
[表1]
如表1所示,根据本发明的实施例1通过防止由在高温高湿下水分渗透造成的界面压敏粘合强度减小而可以在例如高温高湿的恶劣环境下获得优异的耐久性和可靠性。另一方面,对比实施例1显示了在高温下压敏粘合强度降低,而且对比实施例2显示了由于水分渗透造成的界面压敏粘合强度减小。
Claims (17)
1.一种压敏粘合剂组合物,包括:
封装树脂;
多官能活化能射线-可聚合化合物,相对于100重量份的封装树脂,所述多官能活化能射线-可聚合化合物的含量为5-30重量份并且满足化学式2;以及
满足化学式1的硅烷化合物:
[化学式1]
其中,R1为氢或烷基,R2和R3各自独立地为氢或直链、支链或环状烷基,或者R2与R3连接而形成环状烷基,R4、R5和R6各自独立地为氢、烷基或烷氧基,R4、R5和R6中的至少一个为烷氧基,n为1以上的整数,
[化学式2]
其中,R1为氢或具有1-4个碳原子的烷基,n为2以上的整数,X是由具有3-30个碳原子的直链、支链或环状烷基产生的残基。
2.根据权利要求1所述的组合物,其中,活化能射线-可聚合化合物与满足化学式1的硅烷化合物形成交联结构,该交联结构与封装树脂形成半互穿聚合物网络。
3.根据权利要求1所述的组合物,其中,活化能射线-可聚合化合物与满足化学式1的硅烷化合物形成交联结构,以及封装树脂与活化能射线-可聚合化合物或满足化学式1的硅烷化合物形成交联结构,从而形成互穿聚合物网络。
4.根据权利要求1所述的组合物,其中,所述封装树脂是二烯和具有一个碳碳双键的烯烃类化合物的共聚物。
5.根据权利要求1所述的组合物,其中,相对于100重量份的封装树脂,满足化学式1的硅烷化合物的含量为0.1-10重量份。
6.根据权利要求1所述的组合物,进一步包含增粘剂。
7.根据权利要求6所述的组合物,其中,所述增粘剂是氢化环状烯烃类聚合物。
8.根据权利要求6所述的组合物,其中,相对于100重量份的封装树脂,增粘剂的含量为5-100重量份。
9.根据权利要求1所述的组合物,进一步包含自由基引发剂。
10.根据权利要求9所述的组合物,其中,相对于100重量份的活化能射线-可聚合化合物,自由基引发剂的含量为0.2-20重量份。
11.一种满足式1的压敏粘合膜,包括:
压敏粘合层,所述压敏粘合层包含权利要求1所述的压敏粘合剂组合物或者它的交联产物,
其中,在25℃和50%的相对湿度下保持1小时后在5mm/秒的剥离速率和180度的剥离角度下压敏粘合层对衬底的剥离强度为P gf/25mm,以及
在85℃和85%的相对湿度下保持1小时后在5mm/秒的剥离速率和180度的剥离角度下压敏粘合层对衬底的剥离强度为Q gf/25mm:
[式1]
Q≥1.3P。
12.根据权利要求11所述的压敏粘合膜,其中,所述压敏粘合层包含:含有权利要求1所述的压敏粘合剂组合物或者它的交联产物的第一层;以及含有压敏粘合剂树脂或粘合剂树脂的第二层。
13.根据权利要求11所述的压敏粘合膜,当被加工至100μm的厚度时,所述压敏粘合膜在厚度方向上的水蒸气透过率为50g/m2·day以下。
14.根据权利要求11所述的压敏粘合膜,所述膜对于可见光区域的透光率为85%以上。
15.根据权利要求11所述的压敏粘合膜,所述膜的雾度为3%以下。
16.一种用于封装有机电子装置的产品,包括:
衬底;
在衬底上形成的有机电子元件;以及
用于封装所述有机电子元件的根据权利要求11所述的压敏粘合膜。
17.一种制造有机电子装置的方法,包括:
将权利要求11所述的压敏粘合膜施用至其上形成有有机电子元件的衬底上以覆盖有机电子元件;以及
固化所述压敏粘合膜。
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