CN116769259A - 一种发泡量子点光学扩散板 - Google Patents
一种发泡量子点光学扩散板 Download PDFInfo
- Publication number
- CN116769259A CN116769259A CN202310770021.0A CN202310770021A CN116769259A CN 116769259 A CN116769259 A CN 116769259A CN 202310770021 A CN202310770021 A CN 202310770021A CN 116769259 A CN116769259 A CN 116769259A
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- China
- Prior art keywords
- foaming
- quantum dot
- layer
- diffusion plate
- foaming agent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 239000002096 quantum dot Substances 0.000 title claims abstract description 139
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- 238000009792 diffusion process Methods 0.000 title claims abstract description 87
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- 239000004088 foaming agent Substances 0.000 claims abstract description 63
- 238000002360 preparation method Methods 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 23
- 239000004594 Masterbatch (MB) Substances 0.000 claims abstract description 20
- 150000001875 compounds Chemical class 0.000 claims abstract description 10
- 229920000098 polyolefin Polymers 0.000 claims abstract description 7
- 239000003963 antioxidant agent Substances 0.000 claims description 20
- 239000011347 resin Substances 0.000 claims description 19
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- 238000002156 mixing Methods 0.000 claims description 11
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- 210000000497 foam cell Anatomy 0.000 claims description 8
- ATRRKUHOCOJYRX-UHFFFAOYSA-N Ammonium bicarbonate Chemical compound [NH4+].OC([O-])=O ATRRKUHOCOJYRX-UHFFFAOYSA-N 0.000 claims description 7
- 239000004156 Azodicarbonamide Substances 0.000 claims description 7
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- 238000010521 absorption reaction Methods 0.000 claims description 7
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- XOZUGNYVDXMRKW-AATRIKPKSA-N azodicarbonamide Chemical compound NC(=O)\N=N\C(N)=O XOZUGNYVDXMRKW-AATRIKPKSA-N 0.000 claims description 7
- 235000019399 azodicarbonamide Nutrition 0.000 claims description 7
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- 239000012745 toughening agent Substances 0.000 claims description 7
- UIIMBOGNXHQVGW-DEQYMQKBSA-M Sodium bicarbonate-14C Chemical compound [Na+].O[14C]([O-])=O UIIMBOGNXHQVGW-DEQYMQKBSA-M 0.000 claims description 5
- 229920002223 polystyrene Polymers 0.000 claims description 5
- OZAIFHULBGXAKX-UHFFFAOYSA-N 2-(2-cyanopropan-2-yldiazenyl)-2-methylpropanenitrile Chemical compound N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 claims description 4
- 229910000013 Ammonium bicarbonate Inorganic materials 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 4
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 4
- 235000012538 ammonium bicarbonate Nutrition 0.000 claims description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 4
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 239000011736 potassium bicarbonate Substances 0.000 claims description 4
- 229910000028 potassium bicarbonate Inorganic materials 0.000 claims description 4
- 235000015497 potassium bicarbonate Nutrition 0.000 claims description 4
- TYJJADVDDVDEDZ-UHFFFAOYSA-M potassium hydrogencarbonate Chemical compound [K+].OC([O-])=O TYJJADVDDVDEDZ-UHFFFAOYSA-M 0.000 claims description 4
- CZGWDPMDAIPURF-UHFFFAOYSA-N (4,6-dihydrazinyl-1,3,5-triazin-2-yl)hydrazine Chemical compound NNC1=NC(NN)=NC(NN)=N1 CZGWDPMDAIPURF-UHFFFAOYSA-N 0.000 claims description 3
- ZFFMLCVRJBZUDZ-UHFFFAOYSA-N 2,3-dimethylbutane Chemical group CC(C)C(C)C ZFFMLCVRJBZUDZ-UHFFFAOYSA-N 0.000 claims description 3
- ICGLPKIVTVWCFT-UHFFFAOYSA-N 4-methylbenzenesulfonohydrazide Chemical compound CC1=CC=C(S(=O)(=O)NN)C=C1 ICGLPKIVTVWCFT-UHFFFAOYSA-N 0.000 claims description 3
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- VRFNYSYURHAPFL-UHFFFAOYSA-N [(4-methylphenyl)sulfonylamino]urea Chemical compound CC1=CC=C(S(=O)(=O)NNC(N)=O)C=C1 VRFNYSYURHAPFL-UHFFFAOYSA-N 0.000 claims description 3
- 235000012501 ammonium carbonate Nutrition 0.000 claims description 3
- CAMXVZOXBADHNJ-UHFFFAOYSA-N ammonium nitrite Chemical compound [NH4+].[O-]N=O CAMXVZOXBADHNJ-UHFFFAOYSA-N 0.000 claims description 3
- VJRITMATACIYAF-UHFFFAOYSA-N benzenesulfonohydrazide Chemical compound NNS(=O)(=O)C1=CC=CC=C1 VJRITMATACIYAF-UHFFFAOYSA-N 0.000 claims description 3
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- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 2
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- OJMIONKXNSYLSR-UHFFFAOYSA-N phosphorous acid Chemical compound OP(O)O OJMIONKXNSYLSR-UHFFFAOYSA-N 0.000 claims description 2
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- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 3
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- MWRWFPQBGSZWNV-UHFFFAOYSA-N Dinitrosopentamethylenetetramine Chemical compound C1N2CN(N=O)CN1CN(N=O)C2 MWRWFPQBGSZWNV-UHFFFAOYSA-N 0.000 description 2
- 238000011161 development Methods 0.000 description 2
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- 231100000331 toxic Toxicity 0.000 description 2
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- YFYZPVXABJAXSL-UHFFFAOYSA-N 2,3-dinitrosobenzene-1,4-dicarboxamide Chemical compound NC(=O)C1=CC=C(C(N)=O)C(N=O)=C1N=O YFYZPVXABJAXSL-UHFFFAOYSA-N 0.000 description 1
- LLQHSBBZNDXTIV-UHFFFAOYSA-N 6-[5-[[4-[2-(2,3-dihydro-1H-inden-2-ylamino)pyrimidin-5-yl]piperazin-1-yl]methyl]-4,5-dihydro-1,2-oxazol-3-yl]-3H-1,3-benzoxazol-2-one Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)N1CCN(CC1)CC1CC(=NO1)C1=CC2=C(NC(O2)=O)C=C1 LLQHSBBZNDXTIV-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- UHYPYGJEEGLRJD-UHFFFAOYSA-N cadmium(2+);selenium(2-) Chemical class [Se-2].[Cd+2] UHYPYGJEEGLRJD-UHFFFAOYSA-N 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
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- HTEAGOMAXMOFFS-UHFFFAOYSA-N methyl 2-methylprop-2-enoate;prop-2-enoic acid Chemical compound OC(=O)C=C.COC(=O)C(C)=C HTEAGOMAXMOFFS-UHFFFAOYSA-N 0.000 description 1
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Classifications
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Abstract
一种发泡量子点扩散板,制备工艺中采用吸热型发泡剂和放热型发泡剂复配,再与聚烯烃挤出造粒后得到复配发泡剂母粒,通过热平衡发泡使得发泡过程更为可控,泡孔大小和泡孔分布均匀,并改善发泡量子点扩散板的力学性能。
Description
技术领域
本发明涉及光扩散板技术领域,尤其涉及一种发泡量子点光学扩散板。
背景技术
量子点作为一种新兴半导体材料,具备窄发射半峰宽、高色纯度、颜色可调以及可溶液加工等特点。由于其窄发射半峰宽(<20nm),LCD与量子点技术相结合后能够实现高色域覆盖率(NTSC>100%),明显优于使用荧光粉的传统LCD(NTSC<70%)。扩散板是液晶显示器背光中不可或缺的重要部件,能够起到雾化光线的作用。将量子点集成到扩散板中制备具备三明治结构的量子点扩散板,不仅能够对入射光线进行匀化,还能避免使用价格昂贵的水汽阻隔膜,因此在液晶显示领域具备巨大的发展潜力。
随着现有量子点扩散板技术的发展,出现了发泡量子点扩散板,通过在树脂基体内形成若干泡孔,既能够对光线有更好的散射效果,又能够降低量子点扩散板的整体重量。目前主要通过物理发泡和化学发泡两种方式制备发泡量子点扩散板,其中物理发泡需要专用的发泡设备,因此会增加该种发泡方式的成本。化学发泡往往通过化学发泡剂受热分解产生气体来形成泡孔。常用的发泡剂有吸热型发泡剂(例如碳酸氢纳)和放热型发泡剂(例如偶氮二甲酰胺)。单一类型发泡剂在受热分解过程中存在吸热/放热现象,发泡过程不易控制,泡孔的大小均一性差,同时会使挤出成型中树脂熔体流动速率产生波动,对制品的力学性能产生影响。
CN202211137395.0公开一种微发泡量子点扩散板及其制备方法,所述量子点扩散板由三层结构构成,其由上发泡层、量子点发泡层和下发泡层组成;其中,所述上、下发泡层均包含高阻隔高分子聚合物材料、抗氧剂和光扩散剂;所述量子点发泡层包含绿色量子点、红色量子点、常规光学高分子聚合物材料、抗氧剂和光扩散剂。该技术的不足在于需要特殊的发泡设备进行发泡,同时要求发泡设备精密度高。
CN202210242458.2公开了一种量子点层状体的制备方法,量子点层状体包括量子点复合层,包括:将多个含量子点分散液的封装体、第一聚合物粒料混合,放入第一挤出设备中加热熔融挤出后冷却固化,其中,封装体包括聚合物外壳和位于壳内腔的量子点分散液,量子点分散液包括量子点和溶剂,加热熔融的温度高于溶剂的沸点,溶剂在加热条件下挥发完毕,得到量子点复合层,加热熔融的温度大于第一聚合物粒料的软化温度且小于聚合物外壳的软化温度。该技术的不足在于所述部分溶剂具备毒性,挥发的溶剂需得到进一步的处理。
CN202210036670.3公开一种发泡量子点复合扩散板及其制备工艺,在基材上添加发泡剂,并形成发泡体,所述发泡体在螺杆及模具内有压力未发泡,在出模具口后压力消失发泡层开始发泡;按照预设计量在另一基材添加红绿量子点母料,通过螺杆融合并形成量子体;对所述发泡体和所述量子体沿不同流道进入至模具内复合塑化,以形成对应的三层结构;处于模具中的所述发泡层和所述量子点层进行流延冷却定型,并于所述模具中形成发泡量子点复合扩散板。该技术的不足在于通过流延成型得到扩散板厚度较小,无法制得厚度超过1mm的扩散板。
CN202111471015.2公开了一种高稳定的微发泡量子点扩散板及其制备方法和应用,其微发泡量子点扩散板,包括如下重量份的组分:树脂基材100份,量子点0.1~0.5份,光扩散剂0.5~2.5份,光稳定剂0.01~0.1份,润滑剂0.02~0.1份,抗氧剂0.2~1份,成核剂0.2~1份;所述微发泡量子点扩散板的泡孔截面密度为1×102~5×105个/cm2,泡孔平均直径为2~10μm。该技术的不足在于需要特殊的发泡设备进行发泡,同时要求发泡设备精密度高。
CN202211522030.X提供一种量子点扩散板的制备工艺优化方法及系统。通过对外观指标集合进行关联性分析生成外观独立指标,根据应用场景匹配外观独立指标阈值,根据量子点扩散板制备日志数据对外观独立指标进行集中值评价,并采用相同方法进行性能独立指标评价,若外观/性能独立指标集中评价值不满足对应独立指标阈值,对制备工艺进行优化生成制备工艺优化结果进行量子点扩散板制备控制。该技术的不足在于未能在制备工艺与外观、性能建立起明确关联性。
CN202110263421.3公开了一种量子点扩散板的制备方法,其包括以下步骤:选取RED量子点与GREEN量子点,将其稀释于有机溶剂中,然后再与树脂融合,进行搅拌混合;选用抗拉强度在45-75N/m2,张力大于22N/mm,膜厚15-17um的网版;将调配好的油墨倒入网版中,调整丝网印刷机印刷参数将油墨均匀印刷在扩散板基材表面;印刷完后,通过IR/方式固化;加印量子点油墨保护层:将固化好的产品,在4-8H内加印刷一层环氧树脂密封保护层。该技术的不足在于无法通过印刷在扩散板表面得到形状复杂的光学结构。
CN202210103396.7公开了涉及一种量子点扩散母粒及其制备方法和应用。本发明所述量子点扩散母粒的制备方法,包括在惰性气体保护下,将量子点分散于溶有部分载体树脂的有机溶剂中,得到混合液A;在惰性气体保护下对混合液A进行加热处理,得到混合液B,使量子点在混合液B中的浓度为10~25wt.%;将剩余的载体树脂加至挤出机的主喂料口,将混合液B经液体泵加至挤出机的中间段,经熔融混合造粒,得到所述量子点扩散母粒。该技术主要解决量子点如何在扩散板中分散与相容性的问题,且该技术涉及使用有机溶剂,有机溶剂在加工过程中无法保证完全除去。
现有技术的发泡量子点扩散板技术无法很好的控制发泡过程,所制备的发泡量子点的泡孔不均匀,并且发泡量子点扩散板力学性能不佳,同时也可能由于使用有机溶剂或者具有毒性的溶剂,导致环境污染问题或者增加了溶剂的处理成本。
发明内容
为解决上述技术问题,本发明提供一种发泡量子点扩散板及其制备方法,通过热平衡发泡使得发泡过程更为可控,泡孔大小和泡孔分布均匀,并改善发泡量子点扩散板的力学性能。
本发明首先提供一种发泡量子点扩散板的制备方法,包括:
S1、将吸热型发泡剂和放热型发泡剂复配,再与聚烯烃挤出造粒后得到复配发泡剂母粒;
S2、将所述复配发泡剂母粒与光学树脂基体、光扩散剂、增韧剂、抗氧化剂混合均匀形成上、下发泡层原料;
S3、将光学树脂基体、红色量子点、绿色量子点混合均匀后形成量子点发光层原料;
S4、将所述混合后的上、下发泡层原料和量子点发光层原料进行三层共挤得到所述发泡量子点扩散板。
步骤S1中,由于采用吸热性发泡剂和发热性发泡剂复配,有效地提高了发泡剂的分散性。
步骤S1中,所述聚烯烃优选为聚乙烯、聚丙烯、聚丁烯,进一步地,优选为低密度聚乙烯。
步骤S1中,所述吸热型发泡剂为碳酸铵、碳酸氢铵、碳酸氢钠、碳酸氢钾、亚硝酸铵中的一种或几种。
步骤S1中,所述放热型发泡剂为偶氮二甲酰胺、偶氮二异丁腈、偶氮二甲酸二异丙酯、偶氮二甲酸二乙酯、N,N-二亚硝基五次甲基四胺、N’N-二甲基-N’N二亚硝基对苯二甲酰胺、苯磺酰肼、对甲苯磺酰肼、4’4-氧化双苯磺酰肼、1,3-二磺酰肼苯、对甲苯磺酰胺基脲、4’4-氯代双苯磺酰胺基脲、2,4,6-三肼基-1,3,5-三嗪中的一种或几种。
步骤S1中,所述复配发泡剂母粒中吸热型发泡剂重量含量为5%~10%,或者6%、7%、8%、9%;所述复配发泡剂母粒中放热型发泡剂重量含量为5%~10%,或者6%、7%、8%、9%;吸热型发泡剂与放热型发泡剂的重量用量比例在1:0.5至1:2之间,最优值为1:1.12。
步骤S2中,所述发泡层中光学树脂基体含量为90%~98%,或者92%、93%、95%、97%;所述发泡层中光扩散剂含量为0.3%~4%,或者0.9%、1.0%、1.5%、2.0%、2.5%、3.0%、3.5%,最优值是2.5%,所述发泡层中增韧剂含量为0.5%~4%,或者0.9%、1.0%、1.5%、2.0%、2.5%、3.0%、3.5%,最优值是3%,所述发泡层中抗氧剂含量为0.1%~1%,或者0.2%、0.3%、0.5%、0.7%、0.9%;所述发泡层中发泡剂含量为0.1%~1%,或者0.2%、0.3%、0.5%、0.7%、0.9%,最优值是0.5%。
步骤S2中,所述光学树脂基体为为聚碳酸酯、聚甲基丙烯酸甲酯、聚苯乙烯、聚丙烯中的一种或几种。
步骤S2中,所述光扩散剂为二氧化钛、二氧化硅、硫酸钙、硫酸钡、氧化锌、有机硅、PS微球中的一种或几种。
步骤S2中,所述增韧剂为顺丁橡胶、丁苯橡胶、苯乙烯-丁二烯-苯乙烯嵌段共聚物、聚烯烃热塑性弹性体、甲基丙烯酸甲酯-丙烯酸酯核壳共聚物中的一种或几种。
步骤S2中,所述抗氧化剂为受阻酚类抗氧剂、有机硫代类抗氧剂、受阻胺类抗氧剂、亚磷酸酯类抗氧剂中的一种或几种。
步骤S3中,所述量子点为CdS、CdSe、CdSeS、ZnS、ZnSe、ZnSeS、ZnCdSeS、InP、CuInS、GaN、GaP、GaAs、InN、InP、InGaP、GalnNP量子点中的一种或两种,三种或者几种。
步骤S3中,所述量子点发光层中光学树脂基体含量为98%~99.8%,或者为98.5%、99.0%、99.4%、99.6%,最优值是99%,所述量子点发光层中红色量子点含量为0.1%~1%,或者为0.2%、0.4%、0.6%、0.8%,最优值是0.2%,所述量子点发光层中绿色量子点含量为0.1%~1%,或者为0.2%、0.4%、0.6%、0.8%,最优值是0.8%。
S4步骤中,将所述原料分别加入到独立的螺杆挤出机加料口中进行三层共挤。
S4步骤中,所述发泡量子点扩散板的厚度为0.8-3mm,优选为0.9-2mm,优选为1.0-1.8mm,最优值是1.5mm。
S4步骤中,所述量子点发光层的厚度与上下发泡层之和的厚度比例是1:4-1:1,优选是1:2,其中上发泡层与下发泡层厚度之比是0.9:1.1-1.1:0.9,优选是1:1。
其中所述上发泡层、量子点发光层、下发泡层的厚度比在2:1:2至1:2:1范围内,最优值是1:1:1。
步骤S4中,所述发泡量子点扩散板的整体密度在0.85~0.95g/cm3范围内,优选在0.86~0.90g/cm3范围内,最优值是0.88g/cm3。
步骤S4中,所述发泡量子点扩散板的表面通过共挤、热压、网点印刷等方式设有凸起的微结构,起到匀光或增光作用。所述微结构为半球形、棱镜、正四面体、正六面体、正八面体、梯台结构中的一种或几种。
本发明同时提供上述制备方法制备得到的发泡量子点扩散板。
本发明同时提供一种发泡量子点扩散板,其为三层的发泡量子点扩散板,上、下层为发泡层,中间层为量子点发光层,上、下发泡层的发泡剂原料为吸热型发泡剂和放热型发泡剂复配,泡孔直径误差为5%-12%,泡孔密度为0.9-2.3*103个/mm3,拉伸强度为20-25MPa,弯曲强度为42-45MPa,冲击强度为2.90-3.30J/m2。
进一步的,所述吸热型发泡剂为碳酸铵、碳酸氢铵、碳酸氢钠、碳酸氢钾、亚硝酸铵中的一种或几种。
进一步的,所述放热型发泡剂为偶氮二甲酰胺、偶氮二异丁腈、偶氮二甲酸二异丙酯、偶氮二甲酸二乙酯、N,N-二亚硝基五次甲基四胺、N’N-二甲基-N’N二亚硝基对苯二甲酰胺、苯磺酰肼、对甲苯磺酰肼、4’4-氧化双苯磺酰肼、1,3-二磺酰肼苯、对甲苯磺酰胺基脲、4’4-氯代双苯磺酰胺基脲、2,4,6-三肼基-1,3,5-三嗪中的一种或几种。
本发明的一种发泡量子点扩散板由前述方法制备得到。
与现有技术相比,本发明所提供的产品具有下述优点:
本发明将吸热型发泡剂与放热型发泡剂复配使用,避免发泡剂在分解产生气体的过程中产生大的热量波动,使得树脂熔体的粘度保持稳定,帮助气体在树脂基体内部更好地分散、成核与气泡生长,发泡过程变得更为可控,可制得泡孔大小与泡孔分布均匀的发泡量子点扩散板。同时,高均一性的泡孔对于发泡量子点扩散板的力学性能也起到提升作用。
附图说明
图1为本发明所述发泡量子点扩散板的制备方法的流程示意图。
图2为本发明所述发泡量子点扩散板的结构示意图,其中1为上发泡层,2为量子点发光层,3为下发泡层,4为分布在发泡层中的泡孔,5为绿色量子点,6为红色量子点。
图3为本发明所述实施例1发泡量子点扩散板表面的显微放大图。
图4为本发明所述实施例2发泡量子点扩散板表面的显微放大图。
图5为本发明所述实施例3发泡量子点扩散板表面的显微放大图。
图6为本发明所述实施例4发泡量子点扩散板表面的显微放大图。
图7为本发明所述实施例5发泡量子点扩散板表面的显微放大图。
图8为本发明所述对比例1发泡量子点扩散板表面的显微放大图。
图9为本发明所述对比例2发泡量子点扩散板表面的显微放大图。
具体实施方式
为了更易理解本发明的结构及所能达成的功能特征和优点,下文将本发明的较佳的实施例,并配合图式做详细说明如下:
实施例1
本实例提供了一种发泡量子点扩散板的制备方法及制备得到的发泡量子点扩散板,具体步骤如下:
本实例中选用的吸热型发泡剂为碳酸氢钠、放热型发泡剂为偶氮二甲酰胺、光学树脂为聚苯乙烯,光扩散剂为有机硅,增韧剂为顺丁橡胶,抗氧化剂为1076抗氧化剂,红绿量子点为CdSe量子点。
复合发泡剂母粒制备:复合发泡剂母粒中碳酸氢钠与偶氮二异丁腈的用量比例为1:1.2。将7g碳酸氢钠、8.4g偶氮二甲酰胺、84.6g低密度聚乙烯进行充分搅拌混合后备用。将混合后的原料加入下料斗中,使用双螺杆挤出机进行共混挤出,挤出温度为125~140℃,将挤出的样条通过水冷后进行切粒,得到复配发泡剂母粒。
发泡层混料:将187.6g聚苯乙烯、5g光扩散剂、6g增韧剂、0.4g抗氧化剂、1g复合发泡剂母粒进行充分搅拌混合后分成两等份备用。
量子点发光层混料:将0.2g红色量子点、0.8g绿色量子点、99g聚苯乙烯进行充分搅拌混合后备用。
板材挤出:将混合后的上、下发泡层原料和量子发光层原料分别加入到三个独立的下料斗中,使用双螺杆挤出机进行共混挤出,挤出温度为210~240℃,经牵引冷却后得到三明治结构的发泡量子点扩散板,厚度为1.5mm。如图一所示,发泡量子点扩散板的发泡层1和发泡层3中分散有泡孔4,量子点层2中分散有红色量子点5和绿色量子点6,各层厚度比为1:1:1。
实施例1发泡量子点扩散板表面的显微放大图如图3所示。
实施例2
实例2与实例1的区别在于复合发泡剂母粒中使用的放热型发泡剂为N,N-二亚硝基五次甲基四胺,发泡量子点扩散板的其余制备过程均与实例1保持一致,在此不在赘述。
实施例2发泡量子点扩散板表面的显微放大图如图4所示。
实施例3
实例3与实例1的区别在于复合发泡剂母粒中使用的放热型发泡剂为对苯磺酰肼,发泡量子点扩散板的其余制备过程均与实例1保持一致,在此不在赘述。
实施例3发泡量子点扩散板表面的显微放大图如图5所示。
实施例4
实例4与实例1的区别在于复合发泡剂母粒中使用的吸热型发泡剂为碳酸氢铵,放热型发泡剂为N,N-二亚硝基五次甲基四胺,发泡量子点扩散板的其余制备过程均与实例1保持一致,在此不在赘述。
实施例4发泡量子点扩散板表面的显微放大图如图6所示。
实施例5
实例5与实例1的区别在于复合发泡剂母粒中使用的吸热型发泡剂为碳酸氢钾,放热型发泡剂为对苯磺酰肼,发泡量子点扩散板的其余制备过程均与实例1保持一致,在此不在赘述。
实施例5发泡量子点扩散板表面的显微放大图如图7所示。
对比例1
对比例1与实例1的区别在于只使用了碳酸氢钠进行发泡剂造粒,其余发泡量子点扩散板的制备均与实例1保持一致,在此不在赘述。
对比例1发泡量子点扩散板表面的显微放大图如图6所示。
对比例2
对比例2与实例1的区别在于只使用了偶氮二甲酰胺进行发泡剂造粒,其余发泡量子点扩散板的制备均与实例1保持一致,在此不在赘述。
对比例2发泡量子点扩散板表面的显微放大图如图7所示。
实施例与对比例中发泡剂的选择与用量如表1所示。
表1
实施例与对比例的泡孔直径误差对比如表2所示,其中泡孔直径误差为样品泡孔平均直径与理论泡孔直径的误差百分比。为体现泡孔大小的均匀性,每个实施例与对比例随机抽取五个样品进行测试。
表2
泡孔直径误差(%) | 样品1 | 样品2 | 样品3 | 样品4 | 样品5 |
实施例1 | 5 | 9 | 8 | 9 | 8 |
实施例2 | 9 | 9 | 10 | 7 | 12 |
实施例3 | 8 | 11 | 8 | 7 | 5 |
实施例4 | 12 | 10 | 7 | 9 | 8 |
实施例5 | 6 | 11 | 9 | 11 | 9 |
对比例1 | 22 | 20 | 24 | 27 | 22 |
对比例2 | 25 | 23 | 24 | 24 | 21 |
实施例与对比例的泡孔密度对比如表3所示。为体现泡孔分布的均匀性,每个实施例与对比例随机抽取五个样品进行测试。
泡孔密度(103个/mm3) | 样品1 | 样品2 | 样品3 | 样品4 | 样品5 |
实施例1 | 2.2 | 2.2 | 1.9 | 2.1 | 2.3 |
实施例2 | 1.0 | 1.2 | 1.1 | 1.3 | 1.0 |
实施例3 | 1.3 | 1.1 | 1.4 | 1.3 | 1.4 |
实施例4 | 1.2 | 0.9 | 1.0 | 1.1 | 1.0 |
实施例5 | 0.8 | 0.8 | 1.1 | 0.9 | 1.0 |
对比例1 | 2.0 | 1.4 | 2.2 | 3.0 | 1.7 |
对比例2 | 0.6 | 1.1 | 1.4 | 0.9 | 1.5 |
实施例与对比例的力学性能对比如表4所示。
表4
由上述实施例及对比例的测试结果可以得出,本发明提供的发泡量子点扩散板通过将吸热型发泡剂与放热型发泡剂复配使用可以得到分布均匀、大小相近的泡孔,同时的发泡量子点扩散板的力学性能也得到提升。
以上所述,仅为本发明的较佳实施例而已,并非用于限定本发明的保护范围。凡是根据本发明内容所做的均等变化与修饰,均涵盖在本发明的专利范围内。
Claims (7)
1.一种发泡量子点扩散板的制备方法,包括:
步骤S1、将吸热型发泡剂和放热型发泡剂复配,再与聚烯烃挤出造粒后得到复配发泡剂母粒;
步骤S2、将所述复配发泡剂母粒与光学树脂基体、光扩散剂、增韧剂、抗氧化剂混合均匀形成上、下发泡层原料;
步骤S3、将光学树脂基体、红色量子点、绿色量子点混合均匀后形成量子点发光层原料;
步骤S4、将所述混合后的上、下发泡层原料和量子点发光层原料进行三层共挤得到所述发泡量子点扩散板。
2.根据权利要求1所述的方法,其特征在于,
步骤S1中,所述聚烯烃优选为聚乙烯、聚丙烯、聚丁烯,进一步地,优选为低密度聚乙烯;
步骤S1中,所述吸热型发泡剂为碳酸铵、碳酸氢铵、碳酸氢钠、碳酸氢钾、亚硝酸铵中的一种或几种;
步骤S1中,所述放热型发泡剂为偶氮二甲酰胺、偶氮二异丁腈、偶氮二甲酸二异丙酯、偶氮二甲酸二乙酯、N,N-二亚硝基五次甲基四胺、N’N-二甲基-N’N二亚硝基对苯二甲酰胺、苯磺酰肼、对甲苯磺酰肼、4’4-氧化双苯磺酰肼、1,3-二磺酰肼苯、对甲苯磺酰胺基脲、4’4-氯代双苯磺酰胺基脲、2,4,6-三肼基-1,3,5-三嗪中的一种或几种;
步骤S1中,所述复配发泡剂母粒中吸热型发泡剂重量含量为5%~10%,或者6%、7%、8%、9%;所述复配发泡剂母粒中放热型发泡剂重量含量为5%~10%,或者6%、7%、8%、9%;吸热型发泡剂与放热型发泡剂的重量用量比例在1:0.5至1:2之间,最优值为1:1.12。
3.根据权利要求1所述的方法,其特征在于,步骤S2中,所述发泡层中光学树脂基体含量为90%~98%,或者92%、93%、95%、97%;所述发泡层中光扩散剂含量为0.3%~4%,或者0.9%、1.0%、1.5%、2.0%、2.5%、3.0%、3.5%,最优值是2.5%,所述发泡层中增韧剂含量为0.5%~4%,或者0.9%、1.0%、1.5%、2.0%、2.5%、3.0%、3.5%,最优值是3%,所述发泡层中抗氧剂含量为0.1%~1%,或者0.2%、0.3%、0.5%、0.7%、0.9%;所述发泡层中发泡剂含量为0.1%~1%,或者0.2%、0.3%、0.5%、0.7%、0.9%,最优值是0.5%;
步骤S2中,所述光学树脂基体为为聚碳酸酯、聚甲基丙烯酸甲酯、聚苯乙烯、聚丙烯中的一种或几种;
步骤S2中,所述光扩散剂为二氧化钛、二氧化硅、硫酸钙、硫酸钡、氧化锌、有机硅、PS微球中的一种或几种;
步骤S2中,所述增韧剂为顺丁橡胶、丁苯橡胶、苯乙烯-丁二烯-苯乙烯嵌段共聚物、聚烯烃热塑性弹性体、甲基丙烯酸甲酯-丙烯酸酯核壳共聚物中的一种或几种;
步骤S2中,所述抗氧化剂为受阻酚类抗氧剂、有机硫代类抗氧剂、受阻胺类抗氧剂、亚磷酸酯类抗氧剂中的一种或几种。
4.根据权利要求1-3之一所述的方法,其特征在于,步骤S3中,所述量子点为CdS、CdSe、CdSeS、ZnS、ZnSe、ZnSeS、ZnCdSeS、InP、CuInS、GaN、GaP、GaAs、InN、InP、InGaP、GalnNP量子点中的一种或两种,三种或者几种;
步骤S3中,所述量子点发光层中光学树脂基体含量为98%~99.8%,或者为98.5%、99.0%、99.4%、99.6%,最优值是99%,所述量子点发光层中红色量子点含量为0.1%~1%,或者为0.2%、0.4%、0.6%、0.8%,最优值是0.2%,所述量子点发光层中绿色量子点含量为0.1%~1%,或者为0.2%、0.4%、0.6%、0.8%,最优值是0.8%。
5.根据权利要求1-4之一所述的方法,其特征在于,S4步骤中,将所述原料分别加入到独立的螺杆挤出机加料口中进行三层共挤;
S4步骤中,所述发泡量子点扩散板的厚度为0.8-3mm,优选为0.9-2mm,优选为1.0-1.8mm,最优值是1.5mm;
S4步骤中,所述量子点发光层的厚度与上下发泡层之和的厚度比例是1:4-1:1,优选是1:2,其中上发泡层与下发泡层厚度之比是0.9:1.1-1.1:0.9,优选是1:1;
其中所述上发泡层、量子点发光层、下发泡层的厚度比在2:1:2至1:2:1范围内,最优值是1:1:1;
步骤S4中,所述发泡量子点扩散板的整体密度在0.85~0.95g/cm3范围内,优选在0.86~0.90g/cm3范围内,最优值是0.88g/cm3;
步骤S4中,所述发泡量子点扩散板的表面设有微结构,起到匀光或增光作用。
6.根据权利要求1-5的方法制备的发泡量子点扩散板。
7.一种发泡量子点扩散板,其为三层的发泡量子点扩散板,上、下层为发泡层,中间层为量子点发光层,上、下发泡层的发泡剂原料为吸热型发泡剂和放热型发泡剂复配,泡孔直径误差为5%-12%,泡孔密度为0.9-2.3*103个/mm3,拉伸强度为20-25MPa,弯曲强度为42-45MPa,冲击强度为2.90-3.30J/m2。
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