TWI634148B - Resin composition for electronic device sealing and electronic device - Google Patents
Resin composition for electronic device sealing and electronic device Download PDFInfo
- Publication number
- TWI634148B TWI634148B TW104106045A TW104106045A TWI634148B TW I634148 B TWI634148 B TW I634148B TW 104106045 A TW104106045 A TW 104106045A TW 104106045 A TW104106045 A TW 104106045A TW I634148 B TWI634148 B TW I634148B
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- Taiwan
- Prior art keywords
- electronic device
- sealing
- resin composition
- component
- hydrocarbon
- Prior art date
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- 238000007789 sealing Methods 0.000 title claims abstract description 126
- 239000011342 resin composition Substances 0.000 title claims abstract description 108
- 229920002857 polybutadiene Polymers 0.000 claims abstract description 34
- 239000005062 Polybutadiene Substances 0.000 claims abstract description 33
- 229920000642 polymer Polymers 0.000 claims abstract description 32
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims abstract description 21
- 239000000126 substance Substances 0.000 claims abstract description 18
- 239000003999 initiator Substances 0.000 claims abstract description 16
- 125000000962 organic group Chemical group 0.000 claims abstract description 10
- 125000004432 carbon atom Chemical group C* 0.000 claims abstract description 9
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 8
- 125000000217 alkyl group Chemical group 0.000 claims abstract description 7
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims abstract description 5
- 239000000758 substrate Substances 0.000 claims description 59
- 150000002430 hydrocarbons Chemical class 0.000 claims description 54
- 239000003566 sealing material Substances 0.000 claims description 49
- 239000000463 material Substances 0.000 claims description 37
- 229930195733 hydrocarbon Natural products 0.000 claims description 36
- 239000004215 Carbon black (E152) Substances 0.000 claims description 35
- 229920005989 resin Polymers 0.000 claims description 35
- 239000011347 resin Substances 0.000 claims description 35
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 33
- 239000004065 semiconductor Substances 0.000 claims description 29
- 239000010409 thin film Substances 0.000 claims description 24
- 239000003795 chemical substances by application Substances 0.000 claims description 22
- 229910052751 metal Inorganic materials 0.000 claims description 19
- 239000002184 metal Substances 0.000 claims description 19
- 239000011521 glass Substances 0.000 claims description 18
- 239000003208 petroleum Substances 0.000 claims description 14
- 229920001083 polybutene Polymers 0.000 claims description 13
- KAKZBPTYRLMSJV-UHFFFAOYSA-N butadiene group Chemical group C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 claims description 11
- 239000000178 monomer Substances 0.000 claims description 11
- 239000003085 diluting agent Substances 0.000 claims description 10
- 229920002367 Polyisobutene Polymers 0.000 claims description 7
- 125000003983 fluorenyl group Chemical group C1(=CC=CC=2C3=CC=CC=C3CC12)* 0.000 claims description 6
- 239000004902 Softening Agent Substances 0.000 claims description 3
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 claims description 2
- RSVDRWTUCMTKBV-UHFFFAOYSA-N sbb057044 Chemical compound C12CC=CC2C2CC(OCCOC(=O)C=C)C1C2 RSVDRWTUCMTKBV-UHFFFAOYSA-N 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 53
- 230000005540 biological transmission Effects 0.000 abstract description 8
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical group C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 91
- -1 and an anode Substances 0.000 description 46
- 239000010408 film Substances 0.000 description 46
- 230000004888 barrier function Effects 0.000 description 43
- 239000011248 coating agent Substances 0.000 description 20
- 238000000576 coating method Methods 0.000 description 20
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 15
- 238000000034 method Methods 0.000 description 15
- 239000000203 mixture Substances 0.000 description 15
- 230000035699 permeability Effects 0.000 description 15
- 239000000853 adhesive Substances 0.000 description 14
- 230000001070 adhesive effect Effects 0.000 description 14
- 150000001875 compounds Chemical class 0.000 description 14
- 230000000694 effects Effects 0.000 description 14
- 239000000945 filler Substances 0.000 description 14
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 12
- 238000005452 bending Methods 0.000 description 11
- 238000005401 electroluminescence Methods 0.000 description 11
- 239000007789 gas Substances 0.000 description 11
- 125000002723 alicyclic group Chemical group 0.000 description 10
- 238000005984 hydrogenation reaction Methods 0.000 description 10
- 239000003381 stabilizer Substances 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 9
- 230000006870 function Effects 0.000 description 9
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- 239000000243 solution Substances 0.000 description 9
- 239000002585 base Substances 0.000 description 8
- 238000002347 injection Methods 0.000 description 8
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- 238000012360 testing method Methods 0.000 description 8
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 7
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 7
- 238000005229 chemical vapour deposition Methods 0.000 description 7
- 230000005525 hole transport Effects 0.000 description 7
- 239000001301 oxygen Substances 0.000 description 7
- 229910052760 oxygen Inorganic materials 0.000 description 7
- 229920006295 polythiol Polymers 0.000 description 7
- 229920003048 styrene butadiene rubber Polymers 0.000 description 7
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 7
- HECLRDQVFMWTQS-RGOKHQFPSA-N 1755-01-7 Chemical compound C1[C@H]2[C@@H]3CC=C[C@@H]3[C@@H]1C=C2 HECLRDQVFMWTQS-RGOKHQFPSA-N 0.000 description 6
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 6
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 6
- 239000000470 constituent Substances 0.000 description 6
- 238000011156 evaluation Methods 0.000 description 6
- 238000005755 formation reaction Methods 0.000 description 6
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- 239000000047 product Substances 0.000 description 6
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 5
- 239000003963 antioxidant agent Substances 0.000 description 5
- 230000003078 antioxidant effect Effects 0.000 description 5
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 238000005240 physical vapour deposition Methods 0.000 description 5
- 230000001681 protective effect Effects 0.000 description 5
- 238000004544 sputter deposition Methods 0.000 description 5
- 230000001629 suppression Effects 0.000 description 5
- 238000007738 vacuum evaporation Methods 0.000 description 5
- KWOLFJPFCHCOCG-UHFFFAOYSA-N Acetophenone Chemical compound CC(=O)C1=CC=CC=C1 KWOLFJPFCHCOCG-UHFFFAOYSA-N 0.000 description 4
- 229910002012 Aerosil® Inorganic materials 0.000 description 4
- 229920002799 BoPET Polymers 0.000 description 4
- 239000013032 Hydrocarbon resin Substances 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 4
- ISAOCJYIOMOJEB-UHFFFAOYSA-N benzoin Chemical compound C=1C=CC=CC=1C(O)C(=O)C1=CC=CC=C1 ISAOCJYIOMOJEB-UHFFFAOYSA-N 0.000 description 4
- 239000012965 benzophenone Substances 0.000 description 4
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical class C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 4
- WERYXYBDKMZEQL-UHFFFAOYSA-N butane-1,4-diol Chemical compound OCCCCO WERYXYBDKMZEQL-UHFFFAOYSA-N 0.000 description 4
- 229910052791 calcium Inorganic materials 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 239000007822 coupling agent Substances 0.000 description 4
- 150000002148 esters Chemical class 0.000 description 4
- 229920006270 hydrocarbon resin Polymers 0.000 description 4
- 229910010272 inorganic material Inorganic materials 0.000 description 4
- 239000011147 inorganic material Substances 0.000 description 4
- 239000003921 oil Substances 0.000 description 4
- YRHRIQCWCFGUEQ-UHFFFAOYSA-N thioxanthen-9-one Chemical compound C1=CC=C2C(=O)C3=CC=CC=C3SC2=C1 YRHRIQCWCFGUEQ-UHFFFAOYSA-N 0.000 description 4
- YXFVVABEGXRONW-UHFFFAOYSA-N toluene Substances CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 4
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 4
- 229920002554 vinyl polymer Polymers 0.000 description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical group C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 3
- 239000005977 Ethylene Substances 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
- 230000002411 adverse Effects 0.000 description 3
- 239000010405 anode material Substances 0.000 description 3
- 239000011575 calcium Substances 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Substances [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 239000010406 cathode material Substances 0.000 description 3
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
- 238000004132 cross linking Methods 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 239000003989 dielectric material Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
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- RAXXELZNTBOGNW-UHFFFAOYSA-N imidazole Natural products C1=CNC=N1 RAXXELZNTBOGNW-UHFFFAOYSA-N 0.000 description 3
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 3
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- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 3
- 238000005268 plasma chemical vapour deposition Methods 0.000 description 3
- 229920002493 poly(chlorotrifluoroethylene) Polymers 0.000 description 3
- 229920000515 polycarbonate Polymers 0.000 description 3
- 239000004417 polycarbonate Substances 0.000 description 3
- 239000005023 polychlorotrifluoroethylene (PCTFE) polymer Substances 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 229920002098 polyfluorene Polymers 0.000 description 3
- 230000005855 radiation Effects 0.000 description 3
- 150000003384 small molecules Chemical class 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 238000002834 transmittance Methods 0.000 description 3
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- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 3
- QNODIIQQMGDSEF-UHFFFAOYSA-N (1-hydroxycyclohexyl)-phenylmethanone Chemical compound C=1C=CC=CC=1C(=O)C1(O)CCCCC1 QNODIIQQMGDSEF-UHFFFAOYSA-N 0.000 description 2
- BQCIDUSAKPWEOX-UHFFFAOYSA-N 1,1-Difluoroethene Chemical compound FC(F)=C BQCIDUSAKPWEOX-UHFFFAOYSA-N 0.000 description 2
- AZQWKYJCGOJGHM-UHFFFAOYSA-N 1,4-benzoquinone Chemical compound O=C1C=CC(=O)C=C1 AZQWKYJCGOJGHM-UHFFFAOYSA-N 0.000 description 2
- 239000012956 1-hydroxycyclohexylphenyl-ketone Substances 0.000 description 2
- KWVGIHKZDCUPEU-UHFFFAOYSA-N 2,2-dimethoxy-2-phenylacetophenone Chemical compound C=1C=CC=CC=1C(OC)(OC)C(=O)C1=CC=CC=C1 KWVGIHKZDCUPEU-UHFFFAOYSA-N 0.000 description 2
- XMLYCEVDHLAQEL-UHFFFAOYSA-N 2-hydroxy-2-methyl-1-phenylpropan-1-one Chemical compound CC(C)(O)C(=O)C1=CC=CC=C1 XMLYCEVDHLAQEL-UHFFFAOYSA-N 0.000 description 2
- 125000000954 2-hydroxyethyl group Chemical group [H]C([*])([H])C([H])([H])O[H] 0.000 description 2
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- MYISVPVWAQRUTL-UHFFFAOYSA-N 2-methylthioxanthen-9-one Chemical compound C1=CC=C2C(=O)C3=CC(C)=CC=C3SC2=C1 MYISVPVWAQRUTL-UHFFFAOYSA-N 0.000 description 2
- FIHBHSQYSYVZQE-UHFFFAOYSA-N 6-prop-2-enoyloxyhexyl prop-2-enoate Chemical compound C=CC(=O)OCCCCCCOC(=O)C=C FIHBHSQYSYVZQE-UHFFFAOYSA-N 0.000 description 2
- COCLLEMEIJQBAG-UHFFFAOYSA-N 8-methylnonyl 2-methylprop-2-enoate Chemical compound CC(C)CCCCCCCOC(=O)C(C)=C COCLLEMEIJQBAG-UHFFFAOYSA-N 0.000 description 2
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- 125000003118 aryl group Chemical group 0.000 description 2
- 229960002130 benzoin Drugs 0.000 description 2
- MQDJYUACMFCOFT-UHFFFAOYSA-N bis[2-(1-hydroxycyclohexyl)phenyl]methanone Chemical compound C=1C=CC=C(C(=O)C=2C(=CC=CC=2)C2(O)CCCCC2)C=1C1(O)CCCCC1 MQDJYUACMFCOFT-UHFFFAOYSA-N 0.000 description 2
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- HPAFOABSQZMTHE-UHFFFAOYSA-N phenyl-(2,4,6-trimethylphenyl)methanone Chemical compound CC1=CC(C)=CC(C)=C1C(=O)C1=CC=CC=C1 HPAFOABSQZMTHE-UHFFFAOYSA-N 0.000 description 2
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- CWERGRDVMFNCDR-UHFFFAOYSA-N thioglycolic acid Chemical compound OC(=O)CS CWERGRDVMFNCDR-UHFFFAOYSA-N 0.000 description 2
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Classifications
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- C08F2/48—Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
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- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
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- C08F222/102—Esters of polyhydric alcohols or polyhydric phenols of dialcohols, e.g. ethylene glycol di(meth)acrylate or 1,4-butanediol dimethacrylate
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- C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
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- C08K5/07—Aldehydes; Ketones
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- C08L23/22—Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefins
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- C09D115/00—Coating compositions based on rubber derivatives
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- C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
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- C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
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Abstract
本發明提供一種可充分抑制水蒸氣透過之電子裝置密封用樹脂組成物、及應用該電子裝置密封用樹脂組成物之電子裝置。
本發明提供一種電子裝置密封用樹脂組成物,其含有(A)以下述化學式(1)表示之末端具有(甲基)丙烯醯基之聚丁二烯聚合物與(B)光聚合起始劑,且不含質量平均分子量為5萬以上之熱可塑性樹脂,
(式中,R1及R2分別表示羥基或H2C=C(R7)-COO-,R3及R4各獨立表示碳數1~16之經取代、未取代之二價有機基,R5、R6、R7分別表示氫原子或碳數1~10之烷基,其內部含有至少1個以下述化學式(2)表示之有機基,l及m各表示0或1之整數,n表示15~150之整數,x:y=0~100:100~0,惟,並無R1及R2均為羥基之情況),
Description
本發明係關於使用於電子裝置之密封用樹脂組成物及使用該密封用樹脂組成物密封之電子裝置。
關於有機電子裝置及彼等之電路已知有各種封裝構造。該等構造一般係由基材與蓋、如發光二極體之配置在基材與蓋之間之活性有機零件、密封活性有機零件並且貼合基材與蓋之密封材所構成。基材與蓋之一或二者係以透明材料,例如透明玻璃或塑膠製作,可使光透過。基材與蓋亦可具有柔軟性,除玻璃或塑膠以外,亦有任一種由鋼構成。前述活性有機零件係形成於基材上,某一樣態係由無機阻隔膜、或由積層無機及有機層而成之複數層阻隔膜構成之被覆膜被覆。被覆膜保護活性有機零件之表面及周邊。密封材係塗佈或貼合於活性有機零件上,但存在被覆膜時則塗佈或貼合於其上。該等密封材係藉由包覆活性有機零件而充滿基材與蓋之間之空間,使基材接著於蓋。
然而,活性有機零件容易因低分子成分、氧
或水蒸氣而劣化。例如,有機電致發光裝置係由陰極、發光層、及陽極所成,利用低的功函數之金屬層作為陽極,保證有效的電子注入及低的作動電壓。低的功函數之金屬與氧及水蒸氣具有化學反應性,此種反應會使裝置之壽命變短。且,氧及水蒸氣與發光有機材料反應而抑制發光。為了防止此種反應之發生,大多如上述於活性有機零件之表面設置被覆膜,但無機阻隔膜難以抑制針孔,無法使活性有機零件完全阻斷來自外部之氧或水蒸氣。因此,包圍活性有機零件之密封材不管有無被覆膜,均以抑制來自外部之氧及水蒸氣,尤其是水蒸氣透過之方式設計。
該種密封材可使用硬化性之薄膜狀密封材(例如,參照專利文獻1)。一般,薄膜狀密封材係設於2個擔體薄膜之間,去除該等擔體薄膜之一者,藉由加壓或加熱加壓所露出之薄膜狀密封材,而與蓋或基材之任一者接著。隨後,去除另一擔體薄膜,使蓋及基材彼此接著。薄膜狀密封材可視需要藉由紫外線輻射或熱予以硬化。
且,亦可使用液狀密封材作為該種密封材(例如,參照專利文獻2)。一般,液狀密封材係塗佈於蓋或基材任一者整面後,與薄膜狀密封材同樣,對蓋或基材之另一者加壓或加熱加壓,藉此可使蓋與基材相互接著。液狀密封材一般需要硬化,藉紫外線輻射或熱而硬化。
薄膜狀密封材一般在室溫下具有比液狀密封材高的黏度。在室溫下使用薄膜狀密封材時,對基材或蓋之潤濕性差,且根據情況密封材幾乎不流動而將空氣夾帶
至密封材與基材之間。為了使密封材流動、達成良好濡濕而使夾帶之空氣達最小量,而考慮在高溫下貼合薄膜狀密封材。加熱溫度有時會超過100℃,且需要特別的裝置。再者,薄膜狀密封材需要使用、去除、及丟棄擔體。
液狀密封材揭示有使用具有環氧基或氧雜環丁基之化合物樹脂之密封材(例如,參照專利文獻2)、或使用具有離子聚合性之氰基丙烯酸酯系單體之密封材(例如,參照專利文獻3)、使用雙酚型環氧丙烯酸酯與環氧樹脂之密封材(例如,參照專利文獻4)。然而,該等之水蒸氣透過之抑制效果或硬化後之耐彎曲性不足。因此,作為水蒸氣透過之抑制效果高、硬化後之耐彎曲性優異之密封材,揭示由以末端具有酯鍵及(甲基)丙烯酸酯基之基修飾之氫化聚丁二烯所成之密封材(例如,參照專利文獻5)。
[專利文獻1]日本特開2013-214366號公報
[專利文獻2]日本特開2004-231938號公報
[專利文獻3]日本特開2008-021480號公報
[專利文獻4]日本特開2006-183002號公報
[專利文獻5]日本專利第4801925號公報
上述專利文獻5所記載之密封材為聚丁二烯,主鏈上不含醚、酯。因此,該聚丁二烯可藉由紫外線輻射或熱之應用而交聯、硬化。因此,水蒸氣透過之抑制效果較高。且由於末端導入(甲基)丙烯酸酯基故交聯點間存在適度距離,交聯點密度不會過高,故硬化後之耐彎曲性優異。且,由於透過具有酯鍵之基具有(甲基)丙烯酸酯基,故疏水度高且亦提高水蒸氣透過之抑制效果。然而使用於活性有機零件之水蒸氣透過之抑制尚不足。
因此,本發明之目的係提供一種可充分抑制水蒸氣透過之電子裝置密封用樹脂組成物、及使用該電子裝置密封用樹脂組成物之電子裝置。
為解決上述課題,本發明之電子裝置密封用樹脂組成物之特徵為含有(A)以下述化學式(1)表示之末端具有(甲基)丙烯醯基之聚丁二烯聚合物、(B)光聚合起始劑,且不含質量平均分子量為5萬以上之熱可塑性樹脂之電子裝置密封用樹脂組成物。
(式中,R1及R2各獨立表示羥基或H2C=C(R7)-COO-
,R3及R4各獨立表示碳數1~16之經取代、未取代之二價有機基,R5、R6、R7各獨立表示氫原子或碳數1~10之烷基,其內部含有至少1個以下述化學式(2)表示之有機基,l及m各獨立表示0或1之整數,n表示15~150之整數,x:y=0~100:100~0,惟,並無R1及R2均為羥基之情況)。
上述電子裝置密封用樹脂組成物較好進一步含有(C)反應性稀釋劑,且前述(A)成分與前述(C)成分之質量比(A):(C)為5:95~50:50。
此外,上述電子裝置密封用樹脂組成物較好進而含有(D)數平均分子量未達5萬之烴化合物,且前述(A)成分及前述(C)成分之合計,與前述(D)成分之質量比[(A)+(C)]:(D)為20:80~70:30。
又,上述電子裝置密封用樹脂組成物較好係前述(D)成分之烴化合物至少含有(d1)烴系軟化劑、及(d2)烴系黏著賦予劑,且前述(d1)成分與前述(d2)成分之質量比(d1):(d2)為20:80~80:20。
又,前述(C)成分之反應性稀釋劑較好為二官能之(甲基)丙烯酸酯單體。
且,上述電子裝置密封用樹脂組成物較好係
前述(d1)成分之烴系軟化劑為聚丁烯或/及聚異丁烯。
另外,上述電子裝置密封用樹脂組成物較好係前述(d2)成分之烴系黏著賦予劑為氫化石油樹脂。
又,上述電子裝置密封用樹脂組成物較好係前述聚丁二烯聚合物之丁二烯骨架所具有之不飽和鍵之50%以上經氫化。
且,為解決上述課題,本發明之電子裝置之特徵係藉由使用上述中任一項所記載之電子裝置密封用樹脂組成物之密封材予以密封。
上述電子裝置較好具有可撓性。
且,上述電子裝置較好為有機裝置,具有活性有機零件,且前述密封材係配置於前述活性有機零件之上、上方、或周圍。
上述有機裝置為有機電致發光裝置,前述活性有機零件亦可由陰極、發光層、及陽極所成。
此外,上述電子裝置亦可為觸控螢幕,具有由玻璃或聚合物所成之基材、與配置於前述基材上之實質上透明之導電性金屬,且前述密封材係配置於前述金屬之上、上方、或周圍。
另外,上述電子裝置亦可為光伏裝置,具有光伏電池或光伏電池陣列,前述密封材係配置於前述光伏電池或前述光伏電池陣列中之任意一個光伏電池之上、上方、或周圍。
此外,上述電子裝置可為薄膜電晶體,具有
半導體層,且前述密封材係配置於前述半導體層之上、上方、或周圍。
本發明之電子裝置密封用樹脂組成物可充分抑制水蒸氣透過。且,本發明之電子裝置由於使用上述電子裝置密封用樹脂組成物密封,故可充分地降低因水蒸氣透過所致之劣化。
1A、1B、1C‧‧‧光伏電池
101A、101B、101C‧‧‧元件狀態之光伏電池
102A、103A、103B、102C‧‧‧接著性封入用層
104A、104B‧‧‧前面側之基材
105A、105B、105C‧‧‧背面側之基材
2A、2B‧‧‧薄膜電晶體
201、208‧‧‧基材
202、209‧‧‧閘極電極
203‧‧‧介電體材料
204‧‧‧表面改質被膜
205‧‧‧半導體層
206、213‧‧‧源極電極
207、214‧‧‧汲極電極
210‧‧‧閘極介電體
211‧‧‧實質之非氟化聚合物層
212‧‧‧有機半導體層
圖1係例示之光伏電池之概略剖面圖。
圖2係例示之光伏電池之概略剖面圖。
圖3係例示之光伏電池之概略剖面圖。
圖4係例示之薄膜電晶體之概略剖面圖。
圖5係例示之薄膜電晶體之概略剖面圖。
以下,針對本發明之實施形態加以詳細說明。又,本說明書中,所謂「(甲基)丙烯酸」意指「丙烯酸」及/或「甲基丙烯酸」。
本發明之實施形態之電子裝置密封用樹脂組成物係含有(A)以下述化學式(1)表示之末端具有(甲基)丙烯醯基之聚丁二烯聚合物、(B)光聚合起始劑,且不含質
量平均分子量為5萬以上之熱可塑性樹脂。
(式中,R1及R2各獨立表示羥基或H2C=C(R7)-COO-,R3及R4各獨立表示碳數1~16之經取代、未取代之二價有機基,R5、R6、R7各獨立表示氫原子或碳數1~10之烷基,其內部含有至少1個以下述化學式(2)表示之有機基,l及m各獨立表示0或1之整數,n表示15~150之整數,x:y=0~100:100~0,惟,並無R1及R2均為羥基之情況)。
(A)聚丁二烯聚合物可藉由於分子末端導入羥基之聚丁二烯聚合物與2-(甲基)丙烯醯氧基乙基異氰酸酯等之胺基甲酸酯化反應而獲得。或者亦可使於分子末端導入羥基之聚丁二烯聚合物與六亞甲基二異氰酸酯等二異氰酸酯反應後,與(甲基)丙烯酸反應而得。
聚丁二烯聚合物之質量平均分子量較好為500
以上未達50,000,更好為1,000以上未達10,000,又更好為1,000以上5,000以下。若分子量為50,000以上,則水蒸氣透過之抑制效果高,但電子裝置密封用樹脂組成物之黏度變高,會有塗佈性下降而使空氣夾帶入電子裝置密封用樹脂組成物與基材之間之情況。分子量未達500時,交聯密度變得太高,會有硬化後之電子裝置密封用樹脂組成物之耐彎曲性不足之情況。又,本發明之質量平均分子量係基於利用凝膠滲透層析儀(GPC)測定且使用聚苯乙烯標準物質製作之校正線計算者。
聚丁二烯樹脂之微細構造係以1,2構造對1,4構造及1,4構造部分之順式對反式構造之比率表示。1,2構造量經常稱為乙烯基含量。聚丁二烯之乙烯基含量可在約5%~約90%變動。順式對反式構造之比例可在約1:10~約10:1變動。
聚丁二烯聚合物亦可經氫化,順式與反式兩種之1,4構造變成乙烯構造,1,2構造變成1-丁烯構造。藉氫化減少雙鍵,提高熱安定性、耐候性、耐藥品性、水蒸氣阻隔性等之情況時,係如下述化學式(3)~(5)所示,丁二烯骨架所具有之不飽和鍵之50%以上,較好80%以上,更好90%以上經氫化。又(A)成分之聚丁二烯聚合物係以化學式(3)~(5)表示之末端具有(甲基)丙烯醯基之聚丁二烯聚合物,係包含丁二烯骨架所具有之不飽和鍵之50%以上經氫化者之概念。
(式(3)~(5)中,R1及R2各獨立表示羥基或H2C=C(R7)-COO-,R3及R4各獨立表示碳數1~16之經取代、未取代之二價有機基,R5、R6、R7各獨立表示氫原子或碳數1~10之烷基,其內部含有至少1個以化學式(2)表示之有機基,l及m各獨立表示0或1之整數,n表示15~150之整數,x:y=0~100:100~0,惟,並無R1及R2均為羥基之情況)。
另一方面,1,4構造較多之高順式聚丁二烯之情況,氫化後之構造接近結晶性之聚乙烯構造,玻璃轉移溫度亦隨著氫化率之增加而上升。此外,1,2構造較多時,1,2構造之鏈上有對排(syndiotactic)或等規(isotactic)之立體規則性時,有展現結晶性之可能性,因該等物性變化,會有伴隨著黏度上升而塗佈性下降,或硬化後之彎曲性不足之情況,故抑制該等時,較好為未達90%之氫化率,更好未達80%。每一分子之羥基平均數在約1~3變動,但較好約1.5~3,更好約1.5~2.5。
(B)光聚合起始劑列舉為例如二苯甲酮系光聚合起始劑、苯乙酮系光聚合起始劑、噻噸酮(thioxanthone)系光聚合起始劑、苯偶因系光聚合起始劑等。
二苯甲酮系光聚合起始劑列舉為例如KAYACURE-BP100(二苯甲酮,日本化藥股份有限公司製)、SANYO OBA(苯甲醯基苯甲酸,日本製紙股份有限公司製)、SANYO OBM(苯甲醯基苯甲酸甲酯,日本製紙股份有限公司製)、TRIGANOL 12(4-苯基二苯甲酮,Akzo)、KAYACURE-MBP(3,3’-二甲基-4-甲氧基二苯甲酮,日本化藥股份有限公司製)、KAYACURE-BMS([4-(甲基苯硫基)苯基]苯基甲酮,日本化藥股份有限公司製)、
ESACURE-TZT(2,4,6-三甲基二苯甲酮,Lamberti)、IRGACURE 651(2,2-二甲氧基-1,2-二苯基乙烷-1-酮,BASF公司製)等。
苯乙酮系光聚合起始劑列舉為例如DAROCUR 1173(2-羥基-2-甲基-1-苯基丙-1-酮,BASF公司製)、DAROCUR 1116(1-(4-異丙基苯基)-2-羥基-2-甲基丙-1-酮,BASF公司製)、IRGACURE 184(1-羥基環己基苯基酮,BASF公司製)、DAROCUR 953(1-(4-十二烷基苯基)-2-羥基-2-甲基丙-1-酮,BASF公司製)、DAROCUR 2959(4-(2-羥基乙氧基)-苯基(2-羥基-2-丙基)酮,BASF公司製造)等。
噻噸酮系光聚合起始劑列舉為例如NISSOCURE-TX(噻噸酮,日本曹達股份有限公司製)、NISSOCURE-MTX(2-甲基噻噸酮,日本曹達股份有限公司製)、KAYACURE-RTX(2,4-二甲基噻噸酮,日本化藥股份有限公司製)、KAYACURE-CTX(2,4-二氯噻噸酮,日本化藥股份有限公司製)、KAYACURE-DETX(2,4-二乙基噻噸酮,日本化藥股份有限公司製)、KAYACURE-DITX(2,4-二異丙基噻噸酮,日本化藥股份有限公司製)等。
苯偶因系光聚合起始劑列舉為例如NISSOCURE-BO(噻噸酮,日本曹達股份有限公司製)、NISSOCURE-MBO(苯偶因甲基醚,日本曹達股份有限公司製)、NISSOCURE-EBO(苯偶因乙基醚,日本曹達股份有限公司製)、IRGACURE 65(苄基甲基縮醛,BASF公司製)
等。
其他光聚合起始劑列舉為1-苯基-1,2-丙二酮-2(鄰-乙氧基羰基)肟等。商品名列舉為例如QUANTACURE-PDO(Ward Blenkinsop公司製)等。
光聚合起始劑之量為有效量,典型上為(甲基)丙烯酸酯每100質量份為0.01~20質量份之範圍。藉由設為該組成,可適度控制經由活性成分生成反應之聚合反應。光聚合起始劑之選擇至少部分依存於密封用樹脂組成物所用之(甲基)丙烯酸酯、及期望之硬化速度,亦可以任意之調配比例使用1種或2種以上。
本發明之電子裝置密封用樹脂組成物不含質量平均分子量為5萬以上之熱可塑性樹脂。若含有質量平均分子量為5萬以上之熱可塑性樹脂,則黏度變高,使塗佈性下降。
本發明之電子裝置密封用樹脂組成物較好含有(C)反應性稀釋劑。(C)反應性稀釋劑係使電子裝置密封用樹脂組成物之黏度降低,而容易塗佈者。且,係電子裝置密封用樹脂組成物硬化時可聚合者,因此與單純之稀釋成分比較,水分之透過性低,可阻止經密封之電子構成要素、活性有機零件暴露於水分,或者抑制至最低限度。再者含有最適量時,可提高水蒸氣阻隔性。又,可在幾乎不增加用以聚合之電子裝置密封樹脂組成物中所含低分子量成分而密封電子裝置,可阻止裝置中之電極等金屬構成要素之腐蝕或抑制至最低限度。
(C)反應性稀釋劑可使用由乙酸乙烯酯等乙烯酯、(甲基)丙烯酸單體、N-乙烯基單體及聚硫醇化合物等選出之液體光聚合起始性單乙烯單體等,而發揮降低黏度之效果,基於易於同時控制(A)聚丁二烯聚合物與硬化系之觀點,以(甲基)丙烯酸單體較佳。
(甲基)丙烯酸單體列舉為例如(甲基)丙烯酸正丁酯、(甲基)丙烯酸2-乙基己酯、(甲基)丙烯酸月桂酯、(甲基)丙烯酸異肉荳蔻酯、(甲基)丙烯酸異硬脂酯、(甲基)丙烯酸正十八烷酯、(甲基)丙烯酸2-羥基乙酯、(甲基)丙烯酸2-羥基丙酯、(甲基)丙烯酸3-羥基丙酯、(甲基)丙烯酸4-羥基丁酯、(甲基)丙烯酸異冰片酯、(甲基)丙烯酸二環戊烯酯、(甲基)丙烯酸二環戊烯氧基乙酯、嗎啉‧(甲基)丙烯酸酯、1,4-丁二醇‧二(甲基)丙烯酸酯、二環戊二烯二羥甲基‧(甲基)丙烯酸酯、環己烷二羥甲基‧二(甲基)丙烯酸酯、己二醇‧二(甲基)丙烯酸酯、壬二醇‧二(甲基)丙烯酸酯、苯氧基乙基‧丙烯酸酯、三環癸烷二甲醇‧二(甲基)丙烯酸酯、三羥甲基丙烷‧三(甲基)丙烯酸酯、參(2-羥基乙基)異氰尿酸酯‧三(甲基)丙烯酸酯、(甲基)丙烯酸與多元醇之酯等。該等中,較好為黏度降低效果大、水蒸氣阻隔性高、多官能之(甲基)丙烯酸酯單體,更好為二官能之(甲基)丙烯酸酯單體。再者較好為藉由與(A)聚丁二烯聚合物組合,而提高水蒸氣阻隔性之效果高之己二醇‧二(甲基)丙烯酸酯、三環癸烷二甲醇‧二(甲基)丙烯酸酯、1,4-丁二醇‧二(甲基)丙烯酸酯。
N-乙烯基單體列舉為例如N,N-二甲基丙烯醯胺、N-乙烯基吡咯啶酮、N-乙烯基己內醯胺等。聚硫醇化合物只要是分子內具有2~6個巰基者即無特別限制,列舉為例如碳數2~20左右之烷二硫醇等脂肪族聚硫醇類;二甲苯二硫醇等芳香族聚硫醇類;以巰基取代醇類之表鹵醇(halohydrin)加成物之鹵原子而成之聚硫醇類;由聚環氧樹脂化合物之硫化氫反應產物所成之聚硫醇類;由分子內具有2~6個羥基之多元醇類、與硫代乙醇酸、β-巰丙酸或β-巰丁酸之酯化合物所成之聚硫醇類等。
本發明之電子裝置密封用樹脂組成物中之(A)成分與(C)成分之含有比率(A):(C),基於黏度、水蒸氣阻隔性之觀點,重要的是以質量比計為5:95~50:50,較好為5:95~40:60,更好為10:90~30:70,又更好為20:80~30:70。藉由使(A)成分與(C)成分為最適之含有比率,可降低黏度,且大幅提高水蒸氣阻隔性。含有比率非最適合時,黏度降低效果小而可能限制塗佈條件,會有即使黏度下降亦無法有效發揮水蒸氣阻隔性之情況。
本發明之電子裝置密封用樹脂組成物較好含有(D)數平均分子量未達5萬之烴化合物。(D)成分之烴化合物在本發明中,係發揮降低電子裝置密封用樹脂組成物之水分透過性,抑制經密封之電子構成要素、活性有機零件暴露於水分之效果者。
烴化合物可具有各種數平均分子量,較好為300以上未達50,000,更好為500以上未達30,000,又更
好為500以上10,000以下。藉由使分子量未達50,000,不會大幅提高電子裝置密封用樹脂組成物之黏度而可提高水蒸氣阻隔性。若數平均分子量未達300,則由於電子裝置密封用樹脂組成物直接或透過薄膜之被覆膜密封活性有機零件,故對密封對象的活性有機零件,尤其是由低功函數之金屬層所成之電極層造成影響,有使裝置壽命變短之情況。又,即使數平均分子量未達50,000,若質量平均分子量為50,000以上,則電子裝置密封用樹脂組成物之黏度大幅提升,顯著損及塗佈性故較不佳。
本發明之電子裝置密封用樹脂組成物中之(A)成分及(C)成分之合計,與(D)成分之含有比率[(A)+(C)]:(D),基於水蒸氣阻隔性、黏度、硬化後之耐彎曲性之觀點,以質量比計可以20:80~70:30調配,[(A)+(C)]:(D)較好為30:70~50:50。
烴化合物可為飽和烴化合物,亦可為不飽和烴化合物。碳-碳雙鍵等不飽和鍵亦可藉氫化、馬來酸化、環氧化、胺基化、或類似方法修飾。氫化具有提高水蒸氣阻隔性、透明性、與其他飽和烴化合物之相溶性而較佳。馬來酸化、環氧化、胺基化具有提高使蓋與基材彼此接著之接著性、與含其他官能基之化合物之相溶性而較佳。
可使用之烴化合物之例列舉為環烷油、鏈烷油、低分子聚異丁烯樹脂、聚丁烯、聚異戊二烯等液狀橡膠、低分子聚乙烯、低分子聚丙烯、環烯烴聚合物、石油
樹脂、松脂樹脂、萜烯系樹脂、或彼等之衍生物等,但並不限於該等。
使用烴化合物時,可使用1種烴化合物或複數種烴化合物之組合,但本發明人等積極檢討之結果,發現藉由至少含有除了水蒸氣阻隔性以外亦具有可塑化效果之(d1)烴系軟化劑、與除水蒸氣阻隔性以外亦具有接著性提高效果之(d2)烴系黏著賦予劑,可以較低黏度獲得水蒸氣阻隔性。
藉由併用(d1)烴系軟化劑及(d2)烴系黏著賦予劑,而獲得黏度低、且高水蒸氣阻隔性之機制並不清楚,但推測如下。亦即,由於(D)成分之烴化合物為低分子化合物,故不會大幅提高硬化前之電子裝置密封樹脂組成物之黏度。另一方面,硬化後,認為(D)成分之烴化合物進入到(A)成分及(B)成分或(A)~(C)成分聚合形成之網目構造之內部而埋填間隙,而提高水蒸氣阻隔性。此處,不利用具有可塑化效果之(d1)烴系軟化劑而僅以(d2)烴系黏著賦予劑時,無法以埋填間隙之方式進入至網目構造中,或者即使進入亦過硬而會產生間隙,故認為無法提高水蒸氣阻隔性。相反地,不利用(d2)烴系黏著賦予劑而僅以(d1)烴系軟化劑時,由於即使埋填網目構造之間隙,烴系化合物本身之水蒸氣阻隔性仍不足,故認為幾乎無法提高水蒸氣阻隔性。
(d1)烴系軟化劑之具體例列舉為CALSOL 5120(環烷系油、Calumet Lubricants Co.公司製)、
KAYDOL(鏈烷系,白色礦油,Witco Co.公司製)、TETRAX(Nippon Oil Co.公司製)、PARAPOL 1300(ExxonMobil Chemical Co.公司製)及INDOPOL H-300(BPO Amoco Co.公司製)、Glissopal(低分子聚異丁烯,BASF公司製)、日石聚丁烯(以異丁烯為主體且一部分經陽離子聚合而得之具有長鏈狀烴之分子構造之聚丁烯,JX日鑛日石能源股份有限公司製)、ESSEN聚丁烯(異丁烯與正丁烯之藉陽離子聚合之聚丁烯,日油股份有限公司製)、PARLEAM(氫化聚丁烯,日油股份有限公司製)、KURAPRENE LIR(液狀異戊二烯橡膠,KURARAY股份有限公司製)、KURAPRENE LBR(液狀丁二烯橡膠,KURARAY股份有限公司製),但並不限於該等。
(d2)烴系黏著賦予劑之例列舉為CLEARON(氫化萜烯系樹脂,YASUHARA CHEMICAL股份有限公司製)、ESTERGUM及SUPER ESTER(氫化松脂系樹脂或氫化松脂酯系樹脂,荒川化學工業股份有限公司製)、PINECRYSTAL(岐化松脂系樹脂或岐化酯松脂系樹脂,荒川化學工業股份有限公司製)、ESCOREZ 5300及5400系列(石油腦因熱分解生成之戊烯、異戊二烯、胡椒鹼(piperine)及1,3-戊二烯等之C5餾份共聚合而得之C5系氫化二環戊二烯系樹脂、ExxonMobil Chemical Co.公司製)、EASTOTAC(C5系氫化二環戊二烯系樹脂,Eastman Chemical Co.公司製)、ESCOREZ 5600系列(部分氫化芳香族修飾二環戊二烯系樹脂,ExxonMobil Chemical Co.公司
製)、ARCON(石油腦因熱分解生成之茚、乙烯基甲苯及α-或β-甲基苯乙烯等之C9餾份共聚合而得之C9系氫化石油樹脂,荒川化學工業股份有限公司製)、I-MARV(C5餾份及C9餾份之共聚合氫化石油樹脂,出光興產股份有限公司製),但不限於該等。
上述以外之例,作為非氫化脂環式烴樹脂列舉為C5、C9、C5/C9烴樹脂、聚萜烯樹脂、芳香族修飾聚萜烯樹脂、或松脂衍生物。使用非氫化脂環式烴樹脂時,典型上係與其他氫化或部分氫化黏著賦予劑併用。非氫化脂環式烴樹脂相對於電子裝置密封用樹脂組成物之總重量可以未達約30質量%之量使用。
烴系黏著賦予劑亦可含氫化石油樹脂,具體而言為氫化脂環式石油樹脂。氫化脂環式石油樹脂之具體例列舉為ESCOREZ 5300系列(ExxonMobil Chemical公司製)、I-MARV P系列(出光興產股份有限公司製)。為了提高其水蒸氣阻隔性及透明性,氫化脂環式石油樹脂亦可為氫化二環戊二烯系樹脂。電子裝置密封用樹脂組成物中可使用之氫化脂環式石油樹脂之質量平均分子量典型為200~5,000,氫化脂環式石油樹脂之質量平均分子量較好為500~3,000。質量平均分子量超過5,000時,會有缺乏接著性,或者與(d1)烴系軟化劑之適合性下降之情況。
烴系黏著賦予劑有時具有可至少部分依存於電子裝置密封用樹脂組成物之接著性、使用溫度、塗佈條件而變化之軟化溫度或軟化點(環球法軟化溫度)。環球法
軟化溫度一般為約50℃~200℃,較好約80℃~150℃。市售之一般烴系黏著賦予劑之環球法軟化溫度之範圍由於為前述範圍故只要使用該等即可。例如ESCOREZ 5300系列之ESCOREZ 5380之軟化點為86℃,ESCOREZ 5300為105℃,ESCOREZ 5320為124℃,ESCOREZ 5340為140℃,故可適當選擇。
使用(d1)烴系軟化劑及(d2)烴系黏著賦予劑時,可使用作為(d1)烴系軟化劑之聚丁烯,與作為(d2)烴系黏著賦予劑之氫化二環戊二烯系樹脂之組合。且,可使用作為(d1)烴系軟化劑之聚丁烯,與作為(d2)烴系黏著賦予劑之非氫化脂環式烴系樹脂之組合,但並不限於該等。
本發明之電子裝置密封用樹脂組成物中,藉由含較多的(d1)烴系軟化劑而提高水蒸氣阻隔性、硬化後之耐彎曲性,且含較多之(d2)烴系黏著賦予劑時水蒸氣阻隔性大幅提升故較佳。(d2)烴系黏著賦予劑由於幾乎為源自石油、精油、松脂之疏水性化合物故水蒸氣阻隔性高。(d1)與(d2)之含有比率(d1):(d2)以質量比計為20:80~80:20時展現相乘效果。
電子裝置密封用樹脂組成物中亦可添加填充劑、偶合劑、紫外線吸收劑、紫外線安定劑、抗氧化劑、安定劑、或該等幾種之組合。添加劑之量典型上係選擇為不對(A)聚丁二烯系聚合物之硬化速度造成不良影響,或不對電子裝置密封用樹脂組成物之物理特性造成不良影響。
可使用之填充劑之例包含鈣或鎂之碳酸鹽(例如,碳酸鈣、碳酸鎂、及白雲石(dolomite))、矽酸鹽(例如,高嶺土、燒成黏土、葉蠟石、膨潤土、絹雲母、沸石、滑石、矽鎂土(attapulgite)、及矽灰石)、矽酸(例如,矽藻土、及二氧化矽)、氫氧化鋁、珍珠岩(pearlite)、硫酸鋇(例如,沉降硫酸鋇)、硫酸鈣(例如,石膏)、亞硫酸鈣、碳黑、氧化鋅、二氧化鈦,但不限於該等。
填充劑亦可具有不同粒徑。例如,期望提供在可見光區域中具有高透過率之電子裝置密封用樹脂組成物時,填充劑之平均一次粒徑較好為1~100nm之範圍,更好為5~50nm之範圍內。且,為了改善低水分子透過性而使用板狀或鱗狀形態之填充劑時,該等之平均粒徑較好為0.1~5μm之範圍內,基於填充劑對密封用樹脂組成物之可分散性之觀點,可使用疏水性表面處理親水性填充劑。疏水性表面處理親水性填充劑可為使任意過去之親水性填充劑藉疏水處理變性而得。例如,可以正辛基三烷氧基矽烷等含疏水基之烷基、烷基或烷基矽烷結合劑、二甲基二氯矽烷及六甲基二矽氮烷等矽烷化劑、具有羥基末端之聚二甲基矽氧烷、硬脂醇等高級醇、或硬脂酸等高級脂肪酸處理親水性填充劑之表面。又,本發明中之平均粒徑係利用雷射繞射散射式粒度分佈測定法求出者。
二氧化矽填充劑之例,以二甲基二氯矽烷處理之製品列舉為例如以AEROSIL-R972、R974或R9768(Nippon Aerosil Co.,Ltd.公司製)銷售,以六甲基二
矽氮烷處理之製品列舉為例如以AEROSIL-RX50、NAX50、NX90、RX200或RX300(Nippon Aerosil Co.,Ltd.公司製)銷售,以辛基矽烷處理之製品列舉為例如以AEROSIL-R805(Nippon Aerosil Co.,Ltd.公司製)銷售,以二甲基矽氧油處理之製品列舉為例如以AEROSIL-RY50、NY50、RY200S、R202、RY200或RY300(Nippon Aerosil Co.,Ltd.公司製),及CAB ASIL TS-720(Cabot Co.,Ltd.公司製)銷售者,但並不限於該等。
填充劑可單獨使用或組合使用。含有填充劑時,所添加之填充劑量相對於電子裝置密封用樹脂組成物總量,一般為0.01~20質量%。
且,添加非作為粒子表面改質劑使用之偶合劑亦可改善電子裝置密封用組成物之接著性。該等偶合劑典型上具有與有機成分反應或相互作用之部分及與無機成分反應或相互作用之部分。有用之偶合劑列舉為例如甲基丙烯氧基丙基甲基二甲氧基矽烷(Shinestsu Chemical Co.,Ltd.公司製,KBM502)、3-巰丙基甲基二甲氧基矽烷(Shinestsu Chemical Co.,Ltd.公司製,KBM802)、及縮水甘油基丙基三甲氧基矽烷(Shinestsu Chemical Co.,Ltd.公司製,KBM403)。
紫外線吸收劑之例列舉為苯并三唑系化合物、噁唑酸醯胺(oxazolic acid amide)系化合物、及二苯甲酮系化合物,但並不限於該等。使用紫外線吸收劑時,紫外線吸收劑相對於密封用樹脂組成物總量可以約0.01質
量%~3質量%之量使用。
可使用之抗氧化劑之例列舉為受阻酚系化合物及磷酸酯系化合物,但並不限於該等。使用抗氧化劑時,抗氧化劑相對於密封用樹脂組成物總量可以約0.01~2質量%之量使用。
可使用之安定劑之例列舉為酚系安定劑、受阻胺系安定劑、咪唑系安定劑、二硫代胺基甲酸酯系安定劑、磷系安定劑、硫酯系安定劑、及吩噻嗪,但並不限於該等。使用安定劑時,安定劑相對於密封用樹脂組成物總量可以約0.001~3質量%之量使用。
電子裝置密封用樹脂組成物可藉習知各種方法調製。例如,電子裝置密封用樹脂組成物可藉由完全混合上述化合物而調製。可使用用以混合組成物之捏合機或3軸輥等任意之混合器。所得組成物可使用作為電子裝置密封用樹脂組成物,亦可與其他成分組合形成電子裝置密封用樹脂組成物。
本發明之電子裝置密封用樹脂組成物可使用網版印刷法或類似方法塗覆於基材、蓋或電子裝置之任意構成要素等上,而密封電子裝置。電子裝置密封用樹脂組成物對基材等之塗覆亦可使用習知方法,例如模嘴塗佈、旋轉塗佈、刮板塗佈、壓延等進行。且,密封時係在常溫(25℃)~100℃,較好常溫(25℃)~80℃下,未施加壓力下貼合,或以1.0MPa以下之壓力加壓30秒~5分鐘進行貼合。隨後,本發明之電子裝置密封用樹脂組成物以紫外線
等照射而硬化,成為作為密封材而密封電子裝置。密封材之厚度可適當設計,例如可為約5~200μm、約10~100μm、或約25~100μm等各種厚度。
本發明之電子裝置密封用樹脂組成物僅含少許水或完全不含,故電子裝置密封用樹脂組成物本身之水分對電子裝置之不良影響抑制在最低限度。且,由於水分之透過性低,故可阻止經封入之電子之構成要素、活性有機零件暴露於水分,或抑制在最低限度。此外,電子裝置密封用樹脂組成物可設計成僅含少許酸性成分或完全不含,故可阻止電子裝置中之電極等金屬構成要素之腐蝕或抑制在最低限度。
且,本發明之電子裝置密封用樹脂組成物呈現良好的接著特性。且,電子裝置密封用樹脂組成物由於具有充分之塗佈性,故於經密封之電子裝置內幾乎不捕捉作為空隙之空氣或完全不捕捉。再者,本發明之電子裝置密封用樹脂組成物可減低在電子裝置用途中使用之接著劑中成為問題之大量氣體釋出。且,本發明之電子裝置密封用樹脂組成物塗佈於基材薄膜上,或塗佈後不使密封用樹脂組成物硬化而照射未達1J/cm2之低的紫外線,成形為薄片狀而作成接著性密封層,亦可改善操作性。又,本說明書中,將包含基材薄膜與接著性密封層之薄片稱為接著性封入用薄片。使用接著性封入用薄片進行密封時,係在50℃~100℃、0.3~1.0MPa之壓力加熱加壓30秒~5分鐘進行貼合。
本發明之電子裝置密封用樹脂組成物在電磁光譜之可見光區域(約380nm~約800nm之波長區域)中亦具有高的透過率(至少約80%)。電子裝置密封用樹脂組成物在可見光區域中具有該高透過率時,可在不遮斷光下作為密封材配置於電子裝置之發光或受光表面之側且進行密封。
此外,本發明之電子裝置密封用樹脂組成物可在多種電子裝置中使用。應用本發明之電子裝置密封用樹脂組成物之電子裝置可將因衝擊或振動產生基體錯開或剝離之密封缺陷之發生抑制至最低限度。此外,作為可使用硬化後提高耐彎曲性之電子裝置密封用樹脂組成物之電子裝置,列舉可撓性顯示器。可使用電子裝置密封用樹脂組成物之電子裝置之其他種類列舉為有機發光二極體、光伏電池、薄膜電晶體及觸控螢幕。
接著,針對上述電子裝置為有機電致發光元件之情況加以說明。有機電致發光元件係至少具有陽極、發光層、及陰極之活性有機零件發光單元,於該活性有機零件上、上方、及周圍塗佈本說明書中記載之任一種電子裝置密封用樹脂組成物並硬化,藉此形成密封材。又,活性有機零件可使以本說明書中記載之複數種電子裝置密封用樹脂組成物分別硬化而成之密封材予以密封,亦可併用使用本發明之電子裝置密封用樹脂組成物形成之密封材與其他密封材予以密封。
有機電致發光裝置中亦有將活性有機零件發
光單元稱為積層體之情況。積層體可具有各種構成,例如包含組裝之1個發光單元、或2個以上之發光單元之組合。且,作為積層體之任意構成要素之一,亦可包含彩色濾光層。
積層體亦可擔持於裝置之基材上。裝置之基材可具有剛性、或為硬質(不容易彎曲),亦可具有可撓性。硬質基材可包含氧化釔安定化氧化鋯(YSZ)、玻璃、及金屬等無機材料,亦可包含聚酯、聚醯亞胺及聚碳酸酯等樹脂材料。具有可撓性之基材亦可包含以樹脂材料構成之例如含氟聚合物(例如三氟化聚乙烯、聚氯三氟乙烯(PCTFE)、偏氟化乙烯(VDF)與氯三氟乙烯(CTFE)之共聚物)、聚醯亞胺、聚碳酸酯、聚對苯二甲酸乙二酯、聚萘二甲酸乙二酯、脂環式聚烯烴、或乙烯-乙烯醇共聚物。
裝置之形狀、構造、尺寸等並無限制。裝置之基材大多具有板狀形狀。裝置可為透明、無色、半透明、或不透明。基材亦可藉包含SiO、SiN、DLF(類鑽石被膜)或DLG(類鑽石玻璃)等無機材料之氣體阻隔層塗覆。氣體阻隔層被膜亦可包含進而於其上交互配置聚合物與無機層之可撓性可見光透過性基材,該等被膜記載於美國專利第7,018,713 B2號(Padiyath等人)中。氣體阻隔層亦可使用真空蒸鍍法、物理蒸鍍法及電漿CVD(化學蒸鍍)等方法形成。
陽極一般係發揮對有機發光層供給電洞之作用。陽極可使用任意習知之陽極材料。陽極材料之功函數
一般為4.0eV以上,陽極材料之較佳例列舉為氧化錫、氧化鋅、氧化銦及銦氧化錫(ITO)等半導體金屬氧化物、如金、銀、鉻及鎳之金屬、及聚苯胺及聚噻吩等有機導電性材料,但並不限於該等。陽極通常包含藉例如真空蒸鍍、濺鍍、離子鍍敷、CVD或電漿CVD形成之薄膜形狀者。任一用途中,陽極均可藉蝕刻等圖型化。陽極厚度可在廣範圍內而有不同,一般約10nm~50μm。
與陽極一起使用之陰極一般係發揮將電子注入有機發光層中之作用。陰極可使用任意習知之陰極材料。陰極材料之功函數通常為4.5eV以下,陰極材料之較佳例列舉為Li、Na、K及Cs等鹼金屬、LiF/Al等複合體材料、Mg及Ca等之鹼土類金屬、金、銀、銦及鐿等稀土類金屬、以及MgAg等合金,但並不限於該等。陰極通常包含藉例如真空蒸鍍、濺鍍、離子鍍敷、CVD或電漿CVD形成之薄膜形狀者。任一用途中,陰極均可藉蝕刻等圖型化。陰極之厚度可在廣範圍內而有不同,一般約10nm~50μm。
配置在陽極與陰極之間之發光單元可具有各種層構造。例如發光單元可為僅含有機發光層之單層構造,或亦可為如有機發光層/電子輸送層、電洞輸送層/有機發光層、電洞輸送層/有機發光層、電洞輸送層/有機發光層/電子輸送層有機發光層/電子輸送層/電子注入層、或電子注入層/電洞輸送層/有機發光層/電子輸送層/電子注入層之多層構造。該等層之各層說明於下。
有機發光層可含有至少一種發光材料,亦可任意含有電洞輸送材料、電子輸送材料等。發光材料並無特別限制,可使用有機電致發光裝置之製造中通常使用之發光材料。發光材料可列舉為金屬錯合物、低分子量螢光性著色材料、螢光性聚合物化合物、或磷光材料。金屬錯合物之較佳例列舉為參(8-羥基喹啉)鋁錯合物(Alq3)、雙(苯并喹啉)鈹錯合物(BeBq2)、雙(8-羥基喹啉)鋅錯合物(Znq2)、及菲繞啉系銪錯合物(Eu(TTA)3(phen)),但並不限於該等。低分子量螢光性著色材料之較佳例包含苝(perylene)、喹吖啶酮(quinacridone)、香豆素及2-噻吩羧酸(DCJTB),但並不限於該等。螢光性聚合物化合物之較佳例列舉為聚(對-伸苯基伸乙烯)(PPV)、9-氯甲基蒽(MEH-PPV)、及聚茀(PF),但並不限於該等。磷光材料之較佳例列舉為八乙基卟啉鉑(platinum octaethylporphyrin)及環金屬化銥化合物。
有機發光層可由如上述之發光材料,使用任意較佳之方法形成。例如,有機發光層可使用真空蒸鍍或物理蒸鍍等薄膜形成方法形成。有機發光層之厚度並無特別限制,一般為約5nm~100nm。
有機發光單元亦可包含由電洞輸送材料所成之電洞輸送層及/或電洞注入層。電洞輸送材料一般係發揮自陽極發射電洞、輸送電洞、且阻斷自陰極發射之電子之作用。電洞輸送材料之較佳例列舉為N,N’-二苯基-N,N’-二(間-甲苯基)聯苯胺(TPD)、N,N,N’,N’-肆(間-甲苯
基)-1,3-苯二胺(PDA)、1,1-雙[N,N-二(對-甲苯基)胺基]苯基]環己烷(TPAC)及4,4’,4”-參[N,N’,N”-三苯基-N,N’,N”-三(間-甲苯基)胺基]-伸苯(m-MTDATA),但並不限於該等。電洞輸送層及電洞注入層可分別使用真空蒸鍍及物理蒸鍍等薄膜形成法形成。該等層之厚度並無特別限制,一般可為5nm~100nm。
有機發光單元可包含由電子輸送材料所成之電子輸送層及/或電子注入層。電子輸送材料係發揮輸送電子、且阻斷自陽極噴射之電洞之作用。電子輸送材料之較佳例列舉為2-(4-第三丁基苯基)-5-(4-聯苯基)-1,3,4-噁二唑(PBD)、及3-(4-第三丁基苯基)-4-苯基-5-(4-聯苯基)-1,2,4-三唑(TAZ)AIQ,但並不限於該等。電子輸送層及電子注入層可分別使用真空蒸鍍及物理蒸鍍等薄膜形成法形成。該等層之厚度並無特別限制,一般可為5nm~100nm。
本說明書中揭示之有機電致發光裝置可藉由使用本發明之電子裝置密封用樹脂組成物之密封材密封上述積層體。密封材可以覆蓋配置於基材上之積層體之露出面整體之層之狀態形成。
有機電致發光裝置由於以本發明之電子裝置密封用樹脂組成物單獨即具有接著特性,故不需要設置用於積層密封材之其他接著層。亦即,省略進而積層接著劑,可使製造製程簡易化,且可強化信賴性。再者,與以往之技術不同,由於可藉電子裝置密封用樹脂組成物被覆
積層體故積層體與蓋之間不會留下中空部。若無中空部則可減少水分透過,藉此可防止裝置特性之劣化同時可獲得小型且薄的裝置。期望有中空部時,亦可使用包圍裝置之接著劑之墊圈。
進而,本發明之電子裝置密封用樹脂組成物在光譜之可見光區域(380nm~800nm)具有透明性。電子裝置密封用樹脂組成物之平均透過性由於為80%以上或90%以上,故電子裝置密封用樹脂組成物實質上不會減低有機電致發光裝置之發光效率。此對於上發光型之有機電致發光裝置特別有益。
亦可積層體外側設置用於保護積層體之上部及底部之不動態薄膜。不動態薄膜可由SiO、SiN、DLG或DLF等無機材料所成,且使用例如真空蒸鍍及濺鍍等被膜形成法形成。不動態薄膜之厚度並無特別限制,一般為約5nm~100nm。
亦可於積層體外側配置可吸收水分及/或氧之材料或由該材料所成之層。該層只要獲得期望之效果亦可配置於任一部位。
除上述構成要素外,有機電致發光裝置可追加包含習知之各種構成要素。
期望全彩裝置時,可將具有白色發光部分之有機電致發光裝置與彩色濾光片組合使用。該組合於3色發光法時並不需要。另外,可組合色轉換法(CCM)、或修正色純度之彩色濾光器之有機電致發光裝置使用。
又,有機電致發光裝置亦可具有保護被膜作為最外層。該保護被膜可為具有水蒸氣阻隔特性或氧阻隔特性之保護被膜,該保護被膜亦稱為「氣體阻隔被膜」或「氣體阻隔層」。氣體阻隔層可以具有水蒸氣阻隔特性之各種材料形成。較佳之材料列舉為包含含氟聚合物(例如,聚萘二甲酸乙二酯、聚三氟化乙烯、聚氯三氟乙烯(PCTEF)、聚醯亞胺、聚碳酸酯、聚對苯二甲酸乙二酯、脂環式聚烯烴及乙烯-乙烯醇共聚物)之聚合物層,但並不限於該等。可使用該聚合物層、或以無機薄膜(例如,氧化矽、氮化矽、氧化鋁、DLG或DLF),使用薄膜形成法(例如濺鍍法)塗佈該聚合物層而得之積層體。此外,氣體阻隔層亦可具有於其上交互配置聚合物層與無機層而成之可撓性可見光透過性基材。該等保護被膜可使用美國專利第7,018,713 B2號(Padiyath等人)所記載者。氣體阻隔層之厚度可在廣範圍內而有不同,一般可為約10nm~500μm。
本說明書中揭示之有機電致發光裝置可利用作為各種領域中之照明或顯示器手段。用途為例如取代螢光燈使用之照明裝置、或電腦裝置、電視受訊機、DVD(數位光碟)、音響機器、測定機械設備、行動電話、PDA(行動資訊終端)及面板等顯示裝置、或背光單元及印表機等之光源陣列等。
又本發明之電子裝置密封用樹脂組成物亦可用於封入由配置於基材上之金屬及金屬氧化物所成之構成
要素。例如,電子裝置密封用樹脂組成物亦可使用於使氧化銦錫(ITO)等實質上透明之導電性金屬沉積於玻璃等基材上、或三乙酸纖維素等聚合物被膜上之觸控螢幕。電子裝置密封用樹脂組成物完全不含有使金屬及/或基材腐蝕之疑慮之酸性要素,或即使含有亦為少量,故可防止金屬及/或基材腐蝕。
此外,本發明之電子裝置密封用樹脂組成物亦可使用作為配置於光伏電池上、上方、或周圍之密封材。光伏電池亦可構成為陣列狀者(相互連接之一連串光伏電池),構成陣列狀之複數個光伏電池之一部分或全部亦可藉本發明之電子裝置密封用樹脂組成物密封。
一般,光伏電池係將光轉換成電所用之半導體裝置,有時亦稱為太陽能電池。光伏電池在暴露於光時,正電極與負電極之間產生電壓,結果使電子流動。電壓之大小與光照射到電池之表面形成之光伏接點之強度成比例。典型上,太陽能電池或太陽能電池模組係將電力供給於特定裝置,或者為了蓄電而產生公電壓之方式相互連接,形成作為單一發電單元之功能之太陽能電池陣列。
光伏電池中使用之半導體材料包含結晶質或多結晶質矽或薄膜矽,例如非晶質、半結晶質矽、鎵砷、二硒化銅銦、有機半導體、CIG等。光伏電池中使用晶圓之半導體材料與薄膜之半導體材料之2種。晶圓之半導體材料係自單一結晶或多結晶錠塊進行機械切割、或利用鑄造製作之半導體材料之薄的薄片。薄膜之半導體材料係使
用濺鍍或化學蒸鍍製程等配置於基材或超基材(supersubstrate)上之半導體材料之連續層。
晶圓及薄膜之光伏電池大多係模組為必須具有1個以上之支撐體之程度之脆性。支撐體可為以剛性,例如以玻璃板剛性材料形成,或亦可為以可撓性材料,例如金屬膜及/或聚醯亞胺或聚對苯二甲酸乙二酯等之較佳聚合物材料所成之薄片而形成。支撐體可係位在光伏電池與光源之間之最上層或基材,該情況下,支撐體使來自光源之光通過。取代此或除此之外,支撐體亦可係位在光伏電池之後之底層。
電子裝置密封用樹脂組成物可配置於光伏電池上、上方、或周圍。藉由使用電子裝置密封用樹脂組成物,可保護光伏電池免受環境影響,及/或可使電池接著於支撐體上。電子裝置密封用樹脂組成物亦可使用作為由相同組成或不同組成所成之幾種密封材中之1種。此外,電子裝置密封用樹脂組成物可直接塗佈於電池上後予以硬化,亦可使預先使電子裝置密封用樹脂組成物成形為薄片狀之接著性密封層積層於光伏電池上,隨後使接著性密封層硬化。
圖1係顯示光伏電池1A之剖面構造之圖,光伏電池1A係以接著性封入用層102A、103A封入元件狀態之光伏電池101A。且,接著性封入用層102A、103A之外側之面上分別設置前面側之基材104A及背面側之基材105A。
圖2係顯示變形例之光伏電池1B之剖面構造之圖,光伏電池1B係以化學蒸鍍等較佳方法使元件狀態之光伏電池101B配置於前面側之基材104B上。接著,將包含例如可卸除之基材薄膜(未圖示)之接著性封入用薄片之接著性封入用層103B配置於光伏電池1B上,剝離基材薄膜且於其上積層背面側之基材105B之狀態,使接著性封入用層103B硬化,藉此密封元件狀態之光伏電池101B。光伏電池1B中,亦可將包含可卸除之基材薄膜之接著性封入用薄片之接著性封入用層103B貼合於背面側之基材105B上,剝離基材薄膜並將該面貼合於元件狀態之光伏電池101B上,使接著性封入用層102B硬化。
圖3係顯示另一例示之光伏電池1C之剖面構造之圖,係以化學蒸鍍等較佳方法將元件狀態之光伏電池101C配置於背面側之基材105C上。接著,使用包含例如可卸除之基材薄膜(未圖示)之接著性封入用薄片之接著性封入用層102C密封元件狀態之光伏電池101C。可視需要利用前面側之基材,亦可使用可卸除之基材薄膜作為前面側之基材。
電子裝置密封用樹脂組成物亦可配置於薄膜電晶體之半導體層之上、上方、或周圍。薄膜電晶體係藉由配置以半導體材料形成之薄膜、與基材接觸之介電體層及金屬而製作之特別種類之場效電晶體。可使用薄膜電晶體驅動發光裝置。
有用之半導體材料針對光伏電池列舉為上述
者及有機半導體。有機半導體列舉為紅螢烯、并四苯(tetracene)、并五苯、苝二醯亞胺、四氰基醌二甲烷等小分子、及包含聚(3-己基噻吩)之聚噻吩、聚茀、聚二乙炔、聚(2,5-伸乙炔伸乙烯)、聚(對-伸苯基伸乙烯)等聚合物之芳香族或其他共軛電子系。無機材料之蒸鍍可使用化學蒸鍍或物理蒸鍍實施。有機材料之蒸鍍可藉小分子之真空蒸鍍或聚合物或小分子之溶液澆鑄實施。
薄膜電晶體一般包含閘極電極、閘極電極上之閘極介電體、與閘極介電體鄰接之源極電極及汲極電極、與閘極介電體鄰接且與源極及汲極電極鄰接之半導體層(例如,參照S.M.Sze,Physics of Semiconductor Devices,第2版,John Wiley and Sons,第492頁,紐約(1981))。該等構成要素可藉各種構成組裝。
薄膜電晶體列舉為例如美國專利第7,279,777 B2號(Bai等人)所揭示之薄膜電晶體。圖4係顯示該薄膜電晶體2A之剖面構造。包含基材201、配置於基材201上之閘極電極202、配置於閘極電極202上之介電體材料203、配置於介電體材料203及基板201上之任意表面改質被膜204、設置於表面改質被膜204上之半導體層205、與半導體層205接觸之源極電極206及汲極電極207。半導體層205之至少一部分係藉由使用本發明之電子裝置密封用樹脂組成物之密封材208密封。
薄膜電晶體之另一例列舉為美國專利第7,352,038 B2號(Kelley等人)所揭示之例示薄膜電晶體。
圖5顯示該薄膜電晶體2B之剖面構造圖。薄膜電晶體2B具有配置於基材209上之閘極電極210,且於閘極電極210上配置閘極介電體211。實質之非氟化聚合物層212係介隔在閘極介電體211與有機半導體層213之間。源極電極214及汲極電極215設於有機半導體層213上。有機半導體層213之至少一部分藉由使用本發明之電子裝置密封用樹脂組成物之密封材216密封。
以下,以實施例針對本發明進一步加以說明,但實施例並非意圖以任何方法限制本發明者。
(實施例1~39及比較例1~7)
以表1~4所示之比例(質量份)調配下述(A)及(C)、(d1)、(d2)之各成分,成分(B)係以(A)成分及(C)成分合計之3質量%之比例調配,且添加甲苯作為適當溶劑調整溶液。以真空容器使溶液脫溶劑,分別獲得實施例1~39及比較例1~7之電子裝置密封用樹脂組成物。針對各組成物之水蒸氣阻隔性、塗佈性、信賴性進行評價。
(A)聚丁二烯聚合物
A1:TE-2000(末端導入丙烯酸基之聚丁二烯,有胺基甲酸酯鍵,未氫化,Mn2000,日本曹達股份有限公司製)
A2:TEAI-1000(末端導入丙烯酸基之聚丁二烯,有胺基甲酸酯鍵,經氫化,Mn1000,日本曹達股份有限公司製)
A3:以下述合成方法所得之胺基甲酸酯丙烯酸酯
A4:SPBDA-S30(末端導入丙烯酸基之聚丁二烯,無胺基甲酸酯鍵,經氫化,Mw3000,大阪有機化學工業股份有限公司)
A5:GI-3000(末端羥基聚丁二烯,無胺基甲酸酯鍵,經氫化,Mn3000,日本曹達)
(胺基甲酸酯丙烯酸酯A3之合成方法)
將日本曹達股份有限公司製GI-3000(末端羥基聚丁二烯,無胺基甲酸酯鍵,經氫化,Mn3000)溶解於環己烷中,邊在40℃攪拌邊緩慢滴加2-丙烯醯氧基乙基異氰酸酯(KARENZ(註冊商標)AOI,昭和電工股份有限公司製),再進行攪拌4小時後,於異丙醇中使結晶沉澱,獲得末端改質氫化丁二烯丙烯酸酯。
(S)苯乙烯丁二烯丙烯酸酯
於氬置換之內容積7L之反應器中添加經脫水純化之環己烷1.90kg、22.9質量%之1,3-丁二烯之己烷溶液2kg、20.0質量%之苯乙烯之環己烷溶液0.573kg、1.6mol/L之2,2-二(四氫呋喃基)丙烷之己烷溶液130.4ml後,添加0.5mol/L之二鋰聚合起始劑108.0ml開始聚合。使混合液升溫至50℃,進行聚合1.5小時後,添加1mol/L之環氧乙烷之環己烷溶液108.0ml,再攪拌2小時後,添加50ml異丙醇。
使所得共聚物之己烷溶液於異丙醇中沉澱,經充分乾燥,獲得分子末端具有羥基之苯乙烯丁二烯橡膠(苯乙烯含量:20質量%,質量平均分子量18,000,分子量分佈1.15)。
使上述所得之分子末端具有羥基之苯乙烯丁二烯橡膠120g溶解於經充分脫水純化之己烷1L中後,以使鎳相對於前述苯乙烯丁二烯橡膠之源自丁二烯之構成單位1,000mol為1mol之方式饋入預先在另一容器中調整之環烷酸鎳、三乙基鋁及丁二烯[分別為1:3:3(莫耳比)]之觸媒液。以2.758MPa(400psi)將氫加壓添加於密閉反應容器中,在110℃進行氫化反應4小時。
隨後,以3mol/m3之鹽酸萃取分離觸媒殘留物,再經離心分離使觸媒殘留物沉降分離。隨後,使分子末端具有羥基之氫化苯乙烯丁二烯橡膠在異丙醇中沉澱,再經充分乾燥,獲得分子末端具有羥基之氫化苯乙烯丁二烯橡膠(苯乙烯含量20質量%,質量平均分子量16,500,氫化率98%,分子量分佈1.1)。
將如此獲得之分子末端具有羥基之氫化苯乙烯丁二烯橡膠溶解於環己烷中,邊在40℃攪拌邊緩慢滴加2-丙烯醯氧基乙基異氰酸酯(「KARENZ(註冊商標)AOI」,昭和電工股份有限公司製),再進行攪拌4小時後,於異丙醇中使結晶沉澱,獲得末端改質氫化苯乙烯丁二烯橡膠。
(B)光聚合起始劑
B1:ESACURE TZT(2,4,6-三甲基二苯甲酮,Lamberti公司製)
B2:ESACURE KIP 100F(聚{2-羥基-2-甲基-1-[4-(1-甲基乙烯基)苯基]丙-1-酮}與2-羥基-2-甲基-1-苯基-丙-1-酮之摻合物,Lamberti公司製)
B3:Irgacure 184(1-羥基環己基苯基酮,BASF公司製)
B4:抗氧化劑IRGANOX 1520L(汽巴特用化學品股份有限公司)
(C)反應性稀釋劑
C1:1,6HX-A(1,6-己二醇二丙烯酸酯,共榮社化學股份有限公司製)
C2:DCP-A(二羥甲基-三環癸烷二丙烯酸酯,共榮社化學股份有限公司製)
C3:CD595(1,10-癸二醇二丙烯酸酯,Sartomer公司製)
C4:Light Ester ID(甲基丙烯酸異癸酯,共榮社化學股份有限公司製)
(d1)烴系軟化劑
d1-1:Nissan聚丁烯200N(聚丁烯,Mn2650,日油股份有限公司製)
d1-2:Glissopal 1000(聚異丁烯,Mn1000,BASF公司製)
d1-3:Nissan聚丁烯015N(聚丁烯,Mn580,日油股份有限公司製)
d1-4:Oppanol B10N(聚異丁烯,Mw36,000,Mn12,000,BASF公司製)
d1-5:KURAPRENE LIR30(聚異戊二烯橡膠,Mw29,000,Mn28,000,KURARAY股份有限公司製)
d1-6:Oppanol B15N(聚異丁烯,Mw75,000,Mn22,000,BASF公司製)
(d2)烴系黏著賦予劑
d2-1:ESCOREZ 5320(C5系氫化二環戊二烯系樹脂,軟化點124℃,Mw640,Mn430,ExxonMobil Chemical公司製)
d2-2:1-MARV P100(C5二環戊二烯/C9共聚合系氫化石油樹脂,軟化點100℃,Mw660,出光興產股份有限公司製)
d2-3:ESCOREZ 1310(C5系石油樹脂,軟化點94℃,Mw1600,Mn1000,ExxonMobil Chemical公司製)
d2-4:PINECRYSTAL KE311(氫化松脂酯系樹脂,軟化點95℃,Mn580,荒川化學工業股份有限公司製)
針對實施例‧比較例之各組成物之水蒸氣阻隔性、塗佈性、信賴性、耐彎曲性進行評價。
(水蒸氣阻隔性)
以使實施例‧比較例之電子裝置密封用樹脂組成物成為50μm厚之方式,以BAKER式佈膠機塗佈於玻璃板上。隨後,以高壓水銀燈照射5J/cm2之波長365nm之紫外線使之硬化,獲得試驗用薄片。以無皺褶或鬆弛之方式將所得薄片裝設於低濕度腔室及高濕度腔室之間,使用壓差式氣體‧蒸氣透過率測定裝置(GTR Tech股份有限公司製,GTR-10XAWT)、氣相層析儀(YANACO技術科技股份有限公司製,G2700T),依據JIS K7129C,求出40℃、90%RH及60℃、90%RH之水蒸氣阻隔性。水蒸氣阻隔性係根據以下評價基準,分5階段進行評價。又,評價中D以上者意指為合格品,E意指不合格品(以下同)。
A極佳
:60℃之透濕度為100g/m2天以下且40℃之透濕度為20g/m2天以下
B非常好
:60℃之透濕度為100g/m2天以下且40℃之透濕度為50g/m2天以下
C佳
:60℃之透濕度為100g/m2天以下且40℃之透濕度為100g/m2天以下
D:普通
:60℃之透濕度為100g/m2天以上且40℃之透濕度為
100g/m2天以下
E不良
:60℃及40℃之透濕度為100g/m2天以上
(塗佈性)
作為條件1係藉以下順序,進行密封用樹脂組成物之塗佈實驗。依據JIS R 3202將1.2mm厚之浮式玻璃調整成30mm×30mm之大小,四邊留下3mm寬作為緣(bezel),以100nm之厚度蒸鍍金屬鈣,製作玻璃基板。另一方面,以成為50μm厚度之方式於另一浮式玻璃上塗佈電子裝置密封用樹脂組成物。使塗佈電子裝置密封用樹脂組成物之面朝下,貼合塗佈玻璃與玻璃基板,獲得基板玻璃/電子裝置密封用樹脂組成物/玻璃之構成之試驗樣品。接著,於試驗樣品之周圍重疊放置2片上述1.2mm厚之浮式玻璃與厚度50μm之聚對苯二甲酸乙二酯薄膜1片,確保無間隙之狀態下以真空層合在80℃、0.6MPa之壓力下加壓5分鐘。自層合機取出加壓後之樣品,以高壓水銀燈照射5J/cm2之波長365nm之紫外線進行硬化後,以目視觀察是否可進行貼合,或二片玻璃之間是否可無孔隙地填充密封用樹脂組成物。條件2係除了以層合機之加壓設為1分鐘以外餘以與條件1相同之條件進行。條件3係除了溫度設為40℃以外餘以與條件2相同之條件進行,條件4係除了以層合機之加壓設為0.1MPa以外餘以與條件3相同之條件進行。塗佈性係根據以下評價基準,分5階
段進行評價。
A極佳
:所有條件均獲得未觀察到孔隙之樣品
B非常好
:條件1、2、3下均獲得未觀察到孔隙之樣品
C佳
:條件1及2下獲得未觀察到孔隙之樣品
D普通
:條件1下獲得未觀察到孔隙之樣品
E不良
:任一條件下均觀察到孔隙或無法貼合
(信賴性)
在40℃、90%RH下處理在塗佈性試驗中未觀察到孔隙之樣品1000小時,隨後,冷卻至室溫(25℃)後,由鈣蒸鍍膜之變化測定透過電子裝置密封用樹脂組成物之水分浸入量。信賴性係根據以下評價基準,分2階段進行評價。
A極佳
:1000小時後之水分浸入量為3mm以下
E不良
:1000小時後之水分浸入量為3mm以上或觀察到孔隙或剝離發生
(耐彎曲性)
以成為25μm厚之方式將實施例‧比較例之電子裝置密封用樹脂組成物塗佈於100μm厚之PET薄膜上。使塗佈電子裝置密封用樹脂組成物之面朝下,以不夾帶孔隙之方式,使塗佈薄膜與另一100μm厚之PET薄膜貼合後,以高壓水銀燈照射5J/cm2之波長365nm紫外線進行硬化,獲得100μm厚PET薄膜/25μm厚之密封用樹脂組成物/100μm厚PET薄膜之構成之試驗樣品。接著,根據JIS K 5600-5-1 1999,使用25mm直徑之心軸進行所得試驗樣品之耐彎曲性試驗。耐彎曲性係根據以下評價基準,分3階段進行評價。
A極佳
:樣品可彎曲,且未觀察到自薄膜剝離、樣品之變色、破裂
D普通
:樣品可彎曲,但觀察到白化等之變色
E不良
:樣品無法彎曲,或者試驗後之樣品觀察到剝離、破裂
如表1~3所示,實施例1~39由於係含有末端具有(甲基)丙烯醯基且具有胺基甲酸酯鍵之聚丁二烯聚合物與光聚合起始劑,且不含質量平均分子量5萬以上之熱可塑性樹脂之組成,故兼具水蒸氣阻隔性與塗佈性,且信賴性之評價中獲得良好之結果。另外,實施例14~17、19~25、28~31、33~39由於係以聚丁二烯聚合物與反應性稀釋劑之質量比為5:95~50:50之範圍含有反應性稀釋劑,故塗佈性獲得改善。且,實施例19~32、34~39係以聚丁二烯聚合物與反應性稀釋劑之合計與數平均分子量未達5萬之烴化合物之質量比為20:80~70:30之範圍含有
數平均分子量未達5萬之烴化合物,故顯示良好的水蒸氣阻隔性。
如表4所示,比較例1、3、4由於聚丁二烯聚合物於末端具有(甲基)丙烯醯基但不具有胺基甲酸酯鍵,故結果為信賴性差。比較例2由於為苯乙烯系聚丁二烯聚合物,故結果為信賴性差。比較例5、7由於不含末端具有(甲基)丙烯醯基且具有胺基甲酸酯鍵之聚丁二烯聚合物,故結果為信賴性差。比較例6由於含有質量平均分子量5萬以上之熱可塑性樹脂,故結果為塗佈性與信賴性均差。
Claims (12)
- 一種電子裝置密封用樹脂組成物,其特徵係含有(A)以下述化學式(1)表示之末端具有(甲基)丙烯醯基之聚丁二烯聚合物、(B)光聚合起始劑、(C)反應性稀釋劑、(D)數平均分子量未達5萬之烴化合物,前述(C)成分之反應性稀釋劑為二官能之(甲基)丙烯酸酯單體,未包含(甲基)丙烯酸二環戊烯氧基乙酯,且不含質量平均分子量為5萬以上之熱可塑性樹脂,前述(A)成分及前述(C)成分之合計,與前述(D)成分之質量比[(A)+(C)]:(D)為20:80~70:30,前述(D)成分之烴化合物至少含有(d1)烴系軟化劑及(d2)烴系黏著賦予劑,且前述(d1)成分與前述(d2)成分之質量比(d1):(d2)為20:80~80:20,
- 如請求項1之電子裝置密封用樹脂組成物,其係前述(A)成分與前述(C)成分之質量比(A):(C)為5:95~50:50。
- 如請求項1之電子裝置密封用樹脂組成物,其中前述(d1)成分之烴系軟化劑為聚丁烯或/及聚異丁烯。
- 如請求項1之電子裝置密封用樹脂組成物,其中前述(d2)成分之烴系黏著賦予劑為氫化石油樹脂。
- 如請求項1之電子裝置密封用樹脂組成物,其中前述聚丁二烯聚合物之丁二烯骨架所具有之不飽和鍵之50%以上經氫化。
- 一種電子裝置,其特徵係藉由使用如請求項1至5中任一項之電子裝置密封用樹脂組成物之密封材予以密封。
- 如請求項6之電子裝置,其具有可撓性。
- 如請求項6或7之電子裝置,其中前述電子裝置為有機裝置,具有活性有機零件,且前述密封材係配置於前述活性有機零件之上、上方、或周圍。
- 如請求項8之電子裝置,其中前述有機裝置為有 機電致發光裝置,前述活性有機零件係由陰極、發光層、及陽極所成。
- 如請求項6或7之電子裝置,其中前述電子裝置為觸控螢幕,具有由玻璃或聚合物所成之基材、與配置於前述基材上之實質上透明之導電性金屬,且前述密封材係配置於前述金屬之上、上方、或周圍。
- 如請求項6或7之電子裝置,其中前述電子裝置為光伏裝置,具有光伏電池或光伏電池陣列,前述密封材係配置於前述光伏電池或前述光伏電池陣列中之任意一個光伏電池之上、上方、或周圍。
- 如請求項6或7之電子裝置,其中前述電子裝置為薄膜電晶體,具有半導體層,且前述密封材係配置於前述半導體層之上、上方、或周圍。
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KR101851483B1 (ko) | 2018-04-23 |
JP2015160921A (ja) | 2015-09-07 |
JP5778304B2 (ja) | 2015-09-16 |
US10196534B2 (en) | 2019-02-05 |
KR20160122791A (ko) | 2016-10-24 |
TW201538587A (zh) | 2015-10-16 |
US20160362576A1 (en) | 2016-12-15 |
CN106062022A (zh) | 2016-10-26 |
WO2015129417A1 (ja) | 2015-09-03 |
CN106062022B (zh) | 2019-01-22 |
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