WO2011155583A1 - 硬化性樹脂組成物およびその硬化物 - Google Patents
硬化性樹脂組成物およびその硬化物 Download PDFInfo
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- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/29—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the material, e.g. carbon
- H01L23/293—Organic, e.g. plastic
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- C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
- C08L83/04—Polysiloxanes
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- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
- C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
- C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
- C08G59/32—Epoxy compounds containing three or more epoxy groups
- C08G59/3254—Epoxy compounds containing three or more epoxy groups containing atoms other than carbon, hydrogen, oxygen or nitrogen
- C08G59/3263—Epoxy compounds containing three or more epoxy groups containing atoms other than carbon, hydrogen, oxygen or nitrogen containing sulfur
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- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/04—Polysiloxanes
- C08G77/12—Polysiloxanes containing silicon bound to hydrogen
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- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/04—Polysiloxanes
- C08G77/14—Polysiloxanes containing silicon bound to oxygen-containing groups
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- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/42—Block-or graft-polymers containing polysiloxane sequences
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/0091—Complexes with metal-heteroatom-bonds
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
- C08K5/092—Polycarboxylic acids
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- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/34—Heterocyclic compounds having nitrogen in the ring
- C08K5/3412—Heterocyclic compounds having nitrogen in the ring having one nitrogen atom in the ring
- C08K5/3432—Six-membered rings
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/56—Organo-metallic compounds, i.e. organic compounds containing a metal-to-carbon bond
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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- 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
- C09J183/00—Adhesives based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Adhesives based on derivatives of such polymers
- C09J183/04—Polysiloxanes
- C09J183/06—Polysiloxanes containing silicon bound to oxygen-containing groups
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
- C08K5/098—Metal salts of carboxylic acids
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/34—Heterocyclic compounds having nitrogen in the ring
- C08K5/3412—Heterocyclic compounds having nitrogen in the ring having one nitrogen atom in the ring
- C08K5/3432—Six-membered rings
- C08K5/3435—Piperidines
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/52—Encapsulations
- H01L33/56—Materials, e.g. epoxy or silicone resin
Definitions
- the present invention relates to a curable resin composition suitable for electrical and electronic materials, particularly for optical semiconductors, and a cured product.
- an epoxy resin composition has been employed as a sealing material for optical semiconductor elements such as LED products in terms of a balance between performance and economy.
- glycidyl ether type epoxy resin compositions typified by bisphenol A type epoxy resins having excellent balance of heat resistance, transparency and mechanical properties have been widely used.
- the sealing material is colored on the LED chip under the influence of short wavelength light, and finally Has been pointed out that illuminance decreases as an LED product.
- Patent Document 3 a resin in which a siloxane skeleton (specifically, a skeleton having Si—O bond) such as silicone resin or silicone-modified epoxy resin is introduced is used as a sealing material.
- a resin having a siloxane skeleton introduced is known to be more stable to light than an epoxy resin, but it is still not sufficient, and further improvement is a problem.
- Patent Document 4 a method of adding a light stabilizer is known (Patent Document 4).
- the light resistance is improved by the addition of the light stabilizer, the resin deteriorates due to heat generated from the LED chip.
- An object of the present invention is to provide a novel curable resin composition that gives a cured product excellent in light-coloring resistance, heat-resistant coloring property and corrosion gas resistance.
- the present invention (1) Curable resin composition containing organopolysiloxane (A) and polyvalent carboxylic acid (B), organometallic salt and / or organometallic complex (C), and light stabilizer (D), provided that organopolysiloxane (A ), Polyvalent carboxylic acid (B), and light stabilizer (D) satisfy the following conditions.
- Y represents a hydrogen atom, an alkyl group having 1 to 50 carbon atoms, an aryl group, or an alkoxy group.
- the curable resin composition according to the above item (1) comprising a compound of the structural formula (1) wherein Y in the structural formula (2) is an alkoxy group having 1 to 20 carbon atoms; (3) Any one of (1) and (2) above, wherein the organometallic salt and / or organometallic complex (C) is a phosphoric ester, a zinc salt of phosphoric acid, and / or a zinc complex having these acids or esters as ligands.
- Curable resin composition according to item, (5) The curable resin composition according to any one of (1) to (4) above, which contains an acid anhydride, (6) Any of (1) to (5) above, wherein the polyvalent carboxylic acid (B) is a compound obtained by reacting a bi- to hexafunctional polyhydric alcohol having 5 or more carbon atoms with a saturated aliphatic cyclic acid anhydride.
- the curable resin composition of the present invention is excellent in corrosion gas resistance, heat-resistant colorability, and light-colorable property, among optical materials, particularly for optical semiconductors (LED products, etc.) used in a living environment such as lighting. It is extremely useful as an adhesive and sealing material.
- the curable resin composition of the present invention contains an organopolysiloxane (A), a polyvalent carboxylic acid (B), an organometallic salt and / or an organometallic complex (C), and a light stabilizer (D).
- an organopolysiloxane (A) an organopolysiloxane having a glycidyl group and / or an epoxycyclohexyl group in its molecule is used.
- the organopolysiloxane is an organopolysiloxane having at least a glycidyl group and / or an epoxycyclohexyl group in the molecule, and is generally a sol-gel using a trialkoxysilane having a glycidyl group or an epoxycyclohexyl group as a raw material. Obtained by reaction.
- a siloxane compound having a three-dimensional network structure described in JP-A-2008-174640 examples thereof include silsesquioxane type organopolysiloxane having a three-dimensional network structure described in JP-A-2008-174640.
- the structure is not particularly limited. However, since a siloxane compound having a simple three-dimensional network structure is too hard, a structure that relaxes the hardness is desired.
- a block structure having a chain-like silicone segment and the aforementioned silsesquioxane structure in one molecule is particularly preferable (hereinafter referred to as a block-type siloxane compound (E)).
- the block-type siloxane compound (E) is not a compound having a repeating unit in a straight chain like a normal block copolymer, but has a network structure that spreads in three dimensions, and has a silsesquioxane structure as a core.
- the chain-like silicone segment is elongated and connected to the next silsesquioxane structure. This structure is effective in the sense of giving a balance between hardness and flexibility to the cured product of the curable composition of the present invention.
- the block type siloxane compound (E) can be produced using, for example, an alkoxysilane (a) represented by the following general formula (3) and a silicone oil (b) represented by the general formula (4) as raw materials,
- the alkoxysilane (c) represented by the general formula (5) can be used as a raw material as necessary.
- the chain-type silicone segment of the block-type siloxane compound (E) is formed from the silicone oil (b), and the three-dimensional network silsesquioxane segment is the alkoxysilane (a) (and the alkoxy added if necessary) Silane (c)).
- each raw material will be described in detail.
- the alkoxysilane (a) is represented by the following general formula (3).
- X in the general formula (3) is not particularly limited as long as it is an organic group containing a glycidyl group and / or an epoxycyclohexyl group.
- an alkyl group having 1 to 4 carbon atoms substituted with a glycidoxy group such as ⁇ -glycidoxyethyl, ⁇ -glycidoxypropyl, ⁇ -glycidoxybutyl, glycidyl group, ⁇ - (3,4-epoxy (Cyclohexyl) ethyl group, ⁇ - (3,4-epoxycyclohexyl) propyl group, ⁇ - (3,4-epoxycycloheptyl) ethyl group, ⁇ - (3,4-epoxycyclohexyl) propyl group, ⁇ - (3,4 Examples thereof include an alkyl group having 1 to 5 carbon atoms substituted with a cyclohexyl group having an oxirane group such as a 4-epoxycyclohexyl) butyl group and a ⁇ - (3,4-epoxycyclohexyl) pentyl group.
- an alkyl group having 1 to 3 carbon atoms substituted with a glycidoxy group an alkyl group having 1 to 3 carbon atoms substituted with a cyclohexyl group having an epoxy group, such as ⁇ -glycidoxyethyl group, ⁇ -Glycidoxypropyl group and ⁇ - (3,4-epoxycyclohexyl) ethyl group are preferable, and ⁇ - (3,4-epoxycyclohexyl) ethyl group is particularly preferable.
- a plurality of R 1 s in the general formula (3) may be the same as or different from each other, and represent a linear, branched or cyclic alkyl group having 1 to 10 carbon atoms.
- R 1 is preferably a methyl group or an ethyl group, particularly preferably a methyl group, from the viewpoint of reaction conditions such as compatibility and reactivity.
- alkoxysilane (a) include ⁇ -glycidoxyethyltrimethoxysilane, ⁇ -glycidoxyethyltriethoxysilane, ⁇ -glycidoxypropyltrimethoxysilane, and ⁇ -glycidoxypropyltriethoxy.
- These alkoxysilanes (a) may be used independently, may use 2 or more types, and can also be used together with the alkoxysilane (c) mentioned later.
- Silicone oil (b) is represented by the following general formula (4)
- a plurality of R 2 may be the same or different from each other, and may be an alkyl group having 1 to 10 carbon atoms, an aryl group having 6 to 14 carbon atoms, or 2 to 10 carbon atoms.
- An alkenyl group of M represents the number of repeating units.
- alkyl group having 1 to 10 carbon atoms examples include linear, branched or cyclic alkyl groups having 1 to 10 carbon atoms, such as a methyl group, an ethyl group, an n-propyl group, an i-propyl group, n-butyl group, i-butyl group, sec-butyl group, t-butyl group, n-pentyl group, i-pentyl group, n-hexyl group, cyclopentyl group, cyclohexyl group, octyl group, 2-ethylhexyl group, nonyl Group, decyl group and the like.
- a methyl group, an ethyl group, and a cyclohexyl group are preferable.
- the aryl group having 6 to 14 carbon atoms include a phenyl group, an o-tolyl group, an m-tolyl group, a p-tolyl group, and a xylyl group.
- the alkenyl group having 2 to 10 carbon atoms include alkenyl groups such as vinyl group, 1-methylvinyl group, allyl group, propenyl group, butenyl group, pentenyl group and hexenyl group.
- R 2 is preferably a methyl group, a phenyl group, a cyclohexyl group or an n-propyl group from the viewpoint of light resistance and heat resistance, and particularly preferably a methyl group or a phenyl group.
- the number m of repeating units of the compound of the general formula (4) shows an average value of 3 to 200, preferably 3 to 100, more preferably 3 to 50.
- m is less than 3, the cured product becomes too hard and the low elastic modulus characteristics are deteriorated. If m exceeds 200, the mechanical properties of the cured product tend to deteriorate, which is not preferable.
- the weight average molecular weight (Mw) of the silicone oil (b) is preferably in the range of 300 to 18,000 (measured by GPC (gel permeation chromatography)). Among these, those having a molecular weight of 300 to 10,000 are preferable in consideration of the elastic modulus at a low temperature, and those having a molecular weight of 300 to 5,000 are more preferable in consideration of compatibility at the time of forming the composition. 1,000 is preferred. If the weight average molecular weight is less than 300, the properties of the chain silicone portion of the characteristic segment are difficult to be obtained, and the properties as a block type may be impaired. If it exceeds 18,000, a severe layer separation structure will be formed. When used as a material, the permeability becomes poor, making it difficult to use.
- the kinematic viscosity of the silicone oil (b) is preferably in the range of 10 to 200 cSt, more preferably 30 to 90 cSt.
- the viscosity is less than 10 cSt, the viscosity of the block type siloxane compound (E) becomes too low and may not be suitable as an optical semiconductor sealing agent.
- the viscosity exceeds 200 cSt, the viscosity of the block type siloxane compound (E) Is unfavorable because it tends to cause an adverse effect on workability.
- preferable silicone oil (b) examples include the following product names.
- PRX413 and BY16-873 are manufactured by Toray Dow Corning Silicone
- X-21-5841 and KF-9701 are manufactured by Shin-Etsu Chemical
- XC96-723, TSR160, YR3370 and YF3800 are manufactured by Momentive.
- XF3905 YF3057, YF3807, YF3802, YF3897, YF3804, XF3905, manufactured by Gelest, DMS-S12, DMS-S14, DMS-S15, DMS-S21, DMS-S27, DMS-S31, DMS-S32, DMS -S33, DMS-S35, DMS-S42, DMS-S45, DMS-S51, PDS-0332, PDS-1615, PDS-9931 and the like.
- the alkoxysilane (c) has a structure represented by the following general formula (5).
- R 3 in the general formula (5) represents a methyl group or a phenyl group.
- a plurality of R 4 in the general formula (5) represents a linear, branched or cyclic alkyl group having 1 to 10 carbon atoms, which may be the same or different.
- R 4 is preferably a methyl group or an ethyl group from the viewpoint of reaction conditions such as compatibility and reactivity.
- preferable alkoxysilane (c) include methyltrimethoxysilane, phenyltrimethoxysilane, methyltriethoxysilane, and phenyltriethoxysilane. Of these, methyltrimethoxysilane and phenyltrimethoxysilane are preferred.
- the alkoxysilane (c) adjusts the molecular weight of the block-type siloxane compound (E), the compatibility with the composition, the heat resistance of the cured product, light resistance, low moisture permeability, low gas permeability, and the like. Therefore, it can be used in combination with alkoxysilane (a).
- the alkoxysilane (c) is preferably used in the range of 5 to 70 mol% of the total of the alkoxysilane (a) and the alkoxysilane (c). 5 to 50 mol% is more preferable, and 10 to 40 mol% is particularly preferable. If it is larger than 70 mol%, the crosslink density of the cured product is lowered and the mechanical strength is lowered, which is not preferable.
- the reaction ratio of alkoxysilane (a), silicone oil (b), and alkoxysilane (c) is based on 1 equivalent of silanol groups of silicone oil (b), with alkoxysilane (a) (optionally alkoxysilane ( When c) is used in combination, the reaction takes place between 1.5 to 200, preferably 2 to 200, particularly preferably 2 to 100, with the alkoxy group in alkoxysilane (a) and alkoxysilane (c)) as an equivalent value. It is preferable to carry out. When the equivalent value exceeds 200, the cured product using the block type siloxane compound (E) becomes too hard, and the desired low elastic modulus characteristic is lowered.
- Production step (1) Step of dealcoholization condensation of silanol-terminated silicone oil and silicon compound having alkoxy group
- Production step (2) Hydrolysis condensation between alkoxy groups of silicon compound having alkoxy group by adding water
- the reaction may be performed in any order as long as it goes through each process.
- ⁇ Manufacturing method (I)> First, as a production process (1), the silicone oil (b) having a silanol group at the terminal and the alkoxysilane (a) (alkoxysilane (c) added if necessary) which is a silicon compound having an alkoxy group are removed. A step of obtaining an alkoxysilane-modified product (d) by performing alkoxysilane modification on the terminal of the silicone oil by an alcohol condensation reaction is performed.
- alkoxysilane (a) which is a silicon compound having an alkoxy group as production step (2) (alkoxysilane (c) added as necessary), and alkoxysilane of silicone oil obtained in production step (1)
- a hydrolysis condensation reaction between alkoxy groups is performed by adding water of alkoxysilane (a) (alkoxysilane (c) added as necessary) which is a silicon compound having an alkoxy group.
- a step of obtaining silsesquioxane (e) having an alkoxy group in the molecule is performed.
- a reaction between the silanol group-containing silicone oil (b) and the silsesquioxane (e) causes a dealcoholization condensation reaction between the alkoxy group remaining in the silsesquioxane structure and the silanol group.
- ⁇ Manufacturing method (c)> First, as a production process (1), the silicone oil (b) having a silanol group at the terminal and the alkoxysilane (a) (alkoxysilane (c) added if necessary) which is a silicon compound having an alkoxy group are removed. After the end of the silicone oil is modified with alkoxysilane by an alcohol condensation reaction to obtain an alkoxysilane-modified product (d), water is added to the system, and the remaining alkoxysilane (a) (alkoxysilane) is produced as a production step (2). (C)), and the method of manufacturing a block-type siloxane compound (E) by performing the hydrolysis-condensation reaction of the alkoxy groups of the alkoxysilane modified body (d) in one pot.
- the production method (c) in which the reaction is sequentially carried out in one pot.
- the production method (c) will be described more specifically.
- the reverse of the manufacturing method (c) described above that is, when the manufacturing process (1) is performed after the manufacturing process (2) as shown in (b), it is formed in the manufacturing process (2).
- the silsesquioxane oligomer having an alkoxy group and the silicone oil (b) are not compatible with each other, the dealcoholization condensation polymerization does not proceed in the subsequent production step (1), and an unreacted silicone oil remains. Is expensive.
- the production process (1) in the one-pot is the first stage reaction and the production process (2) is the second stage reaction
- the silicone oil (b) and the alkoxy The dealcohol condensation of silane (a) (alkoxysilane (c) added if necessary) is carried out, and the terminal of the silicone oil is alkoxysilyl-modified to obtain an alkoxysilane-modified product (d).
- a modified alkoxysilane (D) is considered to exist in a structure represented by the following formula (6).
- R 2 and m have the same meaning as described above, and R 5 represents X or R 3 .
- R 6 represents R 1 when R 5 is X, and R 4 when R 5 is R 3 .
- the alkoxy group In the first stage reaction, if the alkoxy group is reacted in an amount less than 1.0 equivalent with respect to 1 equivalent of the silanol group, the alkoxy group does not exist at the end of the first stage reaction. Further, when the alkoxy group is reacted in an amount of 1.0 to 1.5 equivalents, two or more alkoxy groups in the alkoxysilane (a) (alkoxysilane (c) added if necessary) are converted into silicone oil (b ), And becomes a polymer at the end of the first stage reaction, resulting in gelation. For this reason, it is necessary to make an alkoxy group react with 1.5 equivalent or more with respect to 1 equivalent of silanol groups. From the viewpoint of reaction control, 2.0 equivalents or more are preferable, and 3.0 equivalents or more are more preferable.
- the second stage reaction (production process (2)) in which water is added as it is to carry out hydrolysis condensation between alkoxy groups is performed. Further, in the second stage reaction, the following reactions (I) to (III) occur.
- the production of the block type siloxane compound (E) can be carried out without a catalyst, the reaction progress is slow with no catalyst, and it is preferably carried out in the presence of a catalyst from the viewpoint of shortening the reaction time.
- a catalyst any compound that exhibits acidity or basicity can be used.
- the acidic compound (acid catalyst) include inorganic acids such as hydrochloric acid, sulfuric acid and nitric acid, and organic acids such as formic acid, acetic acid and oxalic acid.
- basic compounds examples include alkali metal hydroxides such as sodium hydroxide, potassium hydroxide, lithium hydroxide, cesium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate
- alkali metal hydroxides such as sodium hydroxide, potassium hydroxide, lithium hydroxide, cesium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate
- Inorganic bases such as alkali metal carbonates such as potassium hydrogen carbonate
- organic bases such as ammonia, triethylamine, diethylenetriamine, n-butylamine, dimethylaminoethanol, triethanolamine, and tetramethylammonium hydroxide can be used.
- an inorganic base is particularly preferable in terms of easy catalyst removal from the product, and sodium hydroxide and potassium hydroxide are particularly preferable.
- the amount of the catalyst added is usually 0.001 to 7.5% by weight, preferably 0, based on the total weight of the alkoxysilane (a) (and the alkoxysilane (c) added if necessary) in the reaction system. 0.01 to 5% by weight.
- a method for adding the catalyst it is added directly or used in a state dissolved in a soluble solvent or the like. Among them, it is preferable to add the catalyst in a state in which the catalyst is dissolved in advance in alcohols such as methanol, ethanol, propanol and butanol.
- the production of the block type siloxane compound (E) can be carried out without a solvent or in a solvent. Moreover, a solvent can also be added in the middle of a manufacturing process. As a solvent in the case of using, especially if it is a solvent which melt
- solvents examples include aprotic polar solvents such as dimethylformamide, dimethylacetamide, and tetrahydrofuran, ketones such as methyl ethyl ketone, methyl isobutyl ketone, and cyclopentanone, ethyl acetate, butyl acetate, ethyl lactate, and butanoic acid.
- aprotic polar solvents such as dimethylformamide, dimethylacetamide, and tetrahydrofuran
- ketones such as methyl ethyl ketone, methyl isobutyl ketone, and cyclopentanone, ethyl acetate, butyl acetate, ethyl lactate, and butanoic acid.
- esters such as isopropyl, alcohols such as methanol, ethanol, propanol and butanol, hydrocarbons such as hexane, cyclohexane, tolu
- reaction in alcohols is preferable from the viewpoint of reaction control, and methanol and ethanol are more preferable.
- the amount of solvent used is not particularly limited as long as the reaction proceeds smoothly, but alkoxysilane (a) (and alkoxysilane (c) added as necessary), a compound of silicone oil (b) Usually, about 0 to 900 parts by weight is used with respect to 100 parts by weight.
- the reaction temperature is usually 20 to 160 ° C., preferably 40 to 140 ° C., particularly preferably 50 to 150 ° C., depending on the amount of catalyst.
- the reaction time is usually 1 to 40 hours, preferably 5 to 30 hours, in each production step.
- the catalyst is removed by quenching and / or washing with water as necessary.
- a solvent that can be separated from water.
- Preferred solvents include ketones such as methyl ethyl ketone, methyl isobutyl ketone and cyclopentanone, esters such as ethyl acetate, butyl acetate, ethyl lactate and isopropyl butanoate, hydrocarbons such as hexane, cyclohexane, toluene and xylene. Can be illustrated.
- the catalyst may be removed only by washing with water, but the reaction is carried out under acidic or basic conditions. It is preferable to remove the adsorbent by filtration after adsorbing the catalyst using Any compound that is acidic or basic can be used for the neutralization reaction.
- the compound exhibiting acidity include inorganic acids such as hydrochloric acid, sulfuric acid and nitric acid, and organic acids such as formic acid, acetic acid and oxalic acid.
- Examples of compounds showing basicity include alkali metal hydroxides such as sodium hydroxide, potassium hydroxide, lithium hydroxide and cesium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate, potassium bicarbonate.
- Inorganic bases such as alkali metal carbonates, phosphoric acid, sodium dihydrogen phosphate, disodium hydrogen phosphate, trisodium phosphate, phosphates such as polyphosphoric acid, sodium tripolyphosphate, ammonia, triethylamine, diethylenetriamine, n-butylamine, Organic bases such as dimethylaminoethanol, triethanolamine, and tetramethylammonium hydroxide can be used.
- inorganic bases or inorganic acids are preferable because they can be easily removed from the product, and phosphates that can more easily adjust the pH to near neutral are more preferable.
- adsorbent examples include activated clay, activated carbon, zeolite, inorganic / organic synthetic adsorbent, ion exchange resin, and the like, and specific examples include the following products.
- activated clay for example, Toshin Kasei Co., Ltd., activated clay SA35, SA1, T, R-15, E, Nikkanite G-36, G-153, G-168 are manufactured by Mizusawa Chemical Co., Ltd. Galeon Earth, Mizuka Ace, etc. are listed.
- activated carbon for example, CL-H, Y-10S, Y-10SF manufactured by Ajinomoto Fine Techno Co., Ltd., S, Y, FC, DP, SA1000, K, A, KA, M, CW130BR manufactured by Phutamura Chemical Co., Ltd. , CW130AR, GM130A, and the like.
- zeolite include, for example, molecular sieves 3A, 4A, 5A, and 13X, manufactured by Union Showa.
- a synthetic adsorbent for example, Kyoward 100, 200, 300, 400, 500, 600, 700, 1000, 2000 manufactured by Kyowa Chemical Co., Ltd., Amberlist 15JWET, 15DRY, manufactured by Rohm and Haas Co., Ltd. 16WET, 31WET, A21, Amberlite IRA400JCl, IRA403BLCl, IRA404JCl, Dow Chemical Co., Dowex 66, HCR-S, HCR-W2, MAC-3, and the like.
- the adsorbent is added to the reaction solution, followed by treatment such as stirring and heating to adsorb the catalyst, and then the adsorbent is filtered and the residue is washed with water to remove the catalyst and adsorbent.
- the reaction After completion of the reaction or after quenching, it can be purified by conventional separation and purification means other than water washing and filtration.
- the purification means include column chromatography, vacuum concentration, distillation, extraction and the like. These purification means may be performed singly or in combination.
- reaction solvent mixed with water is removed from the system by distillation or vacuum concentration after quenching, and then washed with a solvent that can be separated from water. It is preferable.
- the block siloxane compound (E) can be obtained by removing the solvent by vacuum concentration or the like.
- the appearance of the block-type siloxane compound (E) thus obtained is usually colorless and transparent and is a liquid having fluidity at 25 ° C.
- the molecular weight is preferably 800 to 20,000, more preferably 1,000 to 10,000, and particularly preferably 1,500 to 6,000 as the weight average molecular weight measured by GPC. When the weight average molecular weight is less than 800, the heat resistance may be lowered. When the weight average molecular weight is more than 20,000, the viscosity is increased and the workability is adversely affected.
- the weight average molecular weight is a polystyrene equivalent weight average molecular weight (Mw) measured using GPC (gel permeation chromatography) under the following conditions.
- the epoxy equivalent (measured by the method described in JIS K-7236) of the block type siloxane compound (E) is preferably 300 to 1,600 g / eq, more preferably 400 to 1,000 g / eq. Particularly preferred is 450 to 900 g / eq.
- the epoxy equivalent is less than 300 g / eq, the cured product is hard and the elastic modulus tends to be too high, and when it exceeds 1,600 g / eq, the mechanical properties of the cured product tend to deteriorate.
- the viscosity of the block-type siloxane compound (E) is preferably 50 to 20,000 mPa ⁇ s, more preferably 500 to 10,000 mPa ⁇ s, particularly 800 to 5 1,000 mPa ⁇ s is preferred. If the viscosity is less than 50 mPa ⁇ s, the viscosity may be too low to be suitable for use as an optical semiconductor encapsulant, and if it exceeds 20,000 mPa ⁇ s, the viscosity may be too high and workability may be poor. is there.
- the ratio of silicon atoms bonded to three oxygens derived from silsesquioxane in the block-type siloxane compound (E) to the total silicon atoms is preferably 5 to 50 mol%, more preferably 8 to 30 mol%, 10 to 20 mol% is particularly preferable.
- the ratio of silicon atoms bonded to three oxygens derived from silsesquioxane to the total silicon atoms is less than 5 mol%, the cured product tends to be too soft as a characteristic of the chain silicone segment, and surface tack There are concerns about injury. On the other hand, if it exceeds 50 mol%, the cured product becomes too hard as a feature of the silsesquioxane segment, which is not preferable.
- the proportion of silicon atoms present can be determined by 1 H NMR, 29 Si NMR, elemental analysis, etc. of the block type siloxane compound (E).
- the polyvalent carboxylic acid (B) is a compound having at least two or more carboxyl groups and having an aliphatic hydrocarbon group as a main skeleton.
- the polyvalent carboxylic acid is not only a polyvalent carboxylic acid compound having a single structure, but also a mixture of a plurality of compounds having different substituent positions or different substituents, that is, a polyvalent carboxylic acid composition. In the present invention, these are collectively referred to as polyvalent carboxylic acids.
- a bi- to hexafunctional carboxylic acid is particularly preferable.
- the dihydric polyhydric alcohol having 5 or more carbon atoms and an acid anhydride are used. It is preferable that it is the compound obtained by reaction. If the number of carbon atoms is 5 or more, good workability as a sealing material can be ensured.
- the acid anhydride is preferably a polycarboxylic acid which is a saturated aliphatic cyclic acid anhydride.
- the bifunctional to hexafunctional polyhydric alcohol is not particularly limited as long as it is a compound having an alcoholic hydroxyl group, but ethylene glycol, propylene glycol, 1,3-propanediol, 1,2-butanediol, 1, 4-butanediol, 1,5-pentanediol, 1,6-hexanediol, cyclohexanedimethanol, 2,4-diethylpentanediol, 2-ethyl-2-butyl-1,3-propanediol, neopentyl glycol, Diols such as tricyclodecane dimethanol and norbornenediol, triols such as glycerin, trimethylolethane, trimethylolpropane, trimethylolbutane, 2-hydroxymethyl-1,4-butanediol, pentaerythritol, ditrimethylo Tetraols such as propane, and
- Particularly preferred alcohols are alcohols having 5 or more carbon atoms, particularly 1,6-hexanediol, 1,4-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, 1,2-cyclohexanedimethanol, 2, Compounds such as 4-diethylpentanediol, 2-ethyl-2-butyl-1,3-propanediol, neopentyl glycol, tricyclodecane dimethanol, norbornene diol are preferable, and among them, heat resistance and light resistance are imparted and high From the standpoint of maintaining the illuminance retention rate, 2-ethyl-2-butyl-1,3-propanediol, neopentyl glycol, 2,4-diethylpentanediol, 1,4-cyclohexanedimethanol, tricyclodecane dimethanol Branched chain such as norbornenediol Alcohols having concrete or
- acid anhydrides include methyltetrahydrophthalic anhydride, methyl nadic anhydride, nadic anhydride, hexahydrophthalic anhydride, methylhexahydrophthalic anhydride, butanetetracarboxylic anhydride, bicyclo [2,2,1] heptane- 2,3-dicarboxylic acid anhydride, methylbicyclo [2,2,1] heptane-2,3-dicarboxylic acid anhydride, cyclohexane-1,2,4-tricarboxylic acid-1,2-anhydride and the like are preferable, Of these, methylhexahydrophthalic anhydride and cyclohexane-1,2,4-tricarboxylic acid-1,2-anhydride are preferred because of their high transparency.
- one specific reaction condition is that the acid anhydride and polyhydric alcohol are reacted at 40 to 150 ° C. under non-catalytic and solvent-free conditions and heated. It is a technique of taking out as it is after completion. However, it is not limited to this reaction condition.
- Q's represent at least one of a hydrogen atom, a methyl group and a carboxyl group.
- P represents a chain, branched or cyclic fatty acid having 2 to 20 carbon atoms derived from the above-mentioned polyhydric alcohol.
- M is the number of functional groups of the polyhydric alcohol, and is preferably an integer of 2 to 6.
- the curable resin composition of the present invention preferably contains an acid anhydride.
- an acid anhydride By containing an acid anhydride, the viscosity as a curing agent can be arbitrarily adjusted.
- acid anhydrides include phthalic anhydride, trimellitic anhydride, pyromellitic anhydride, maleic anhydride, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, methyl nadic anhydride, nadic anhydride, hexahydrophthalic anhydride Acid, methylhexahydrophthalic anhydride, butanetetracarboxylic anhydride, bicyclo [2,2,1] heptane-2,3-dicarboxylic anhydride, methylbicyclo [2,2,1] heptane-2,3- And acid anhydrides such as dicarboxylic acid anhydride and cyclohexane-1,2,4-tricarboxylic acid-1,2-
- methyltetrahydrophthalic anhydride methylnadic anhydride, nadic anhydride, hexahydrophthalic anhydride, methylhexahydrophthalic anhydride, butanetetracarboxylic anhydride, bicyclo [2,2,1] heptane-2,3-dicarboxylic acid
- An acid anhydride, methylbicyclo [2,2,1] heptane-2,3-dicarboxylic acid anhydride, cyclohexane-1,2,4-tricarboxylic acid-1,2-anhydride and the like are preferable.
- the following formula (8) the following formula (8)
- hexahydrophthalic anhydride methylhexahydrophthalic anhydride, cyclohexane-1,2,4- Tricarboxylic acid-1,2-anhydride is preferable.
- methylhexahydrophthalic anhydride and cyclohexane-1,2,4-tricarboxylic acid-1,2-anhydride are preferable because of high transparency.
- the polyvalent carboxylic acid (B) and the acid anhydride are preferably used in combination, and when used in combination, the use ratio is preferably in the following range.
- W1 / (W1 + W2) 0.05 to 0.65
- W1 shows the compounding weight part of polyhydric carboxylic acid (B)
- W2 shows the compounding weight part of an acid anhydride.
- the range of W1 / (W1 + W2) is preferably 0.05 to 0.65, more preferably 0.10 to 0.65, and particularly preferably 0.3 to 0.6. If it is less than 0.05, there is a strong tendency of acid volatilization to increase during curing, which is not preferable. If it exceeds 0.65, the viscosity becomes high and handling becomes difficult.
- the acid anhydride When the acid anhydride is not contained (except when it remains in a small amount), there is no problem because the shape becomes a solid, a solid state or a crystal.
- polyhydric carboxylic acid (B) and acid anhydride are used in combination, the polyhydric carboxylic acid (B) is produced in an excess of acid anhydride at the time of producing polyhydric carboxylic acid (B), and a mixture of polyvalent carboxylic acid (B) and acid anhydride
- the method of making is also preferable from the viewpoint of simplicity of operation.
- the curable resin composition of the present invention contains an organometallic salt and / or an organometallic complex (C).
- organometallic salt and / or organometallic complex examples include aluminum, manganese, iron, cobalt, nickel, copper, zinc, zirconium, tin, lead, and the like.
- organometallic salt and / or organometallic complex (C) examples include aluminum 2-ethylhexanoate, manganese 2-ethylhexanoate, iron 2-ethylhexanoate, cobalt 2-ethylhexanoate, 2-ethylhexane.
- zinc salts and / or zinc complexes are preferred.
- zinc 2-ethylhexanoate, zinc complexes of phosphoric acid (2-ethylhexyl) and / or salts thereof Zinc stearate, zinc undecylenate, zinc laurate, zinc pehenate, zinc 12-hydroxystearate, zinc montanate, zinc myristate, zinc palmitate, zinc naphthenate, zinc hexate and zinc octylate are preferred.
- zinc 2-ethylhexanoate, zinc complex of phosphoric acid (2-ethylhexyl) and / or a salt thereof, zinc stearate, and zinc undecylenate are more preferable.
- Zinc 2-ethylhexanoate, zinc complex of phosphoric acid (2-ethylhexyl) and / or a salt thereof are particularly preferred.
- commercially available products include Zn-St, Zn-ST 602, Zn-St NZ, ZS-3, ZS-6, ZS-8, ZS-7, ZS-10, ZS-.
- ZS-14, ZS-16 manufactured by Nitto Kasei Kogyo
- XK-614 manufactured by King Industry
- 18% octope Zn, 12% octope Zn, 8% octope Zn manufactured by Hope Pharmaceutical
- examples of the zinc phosphate include LBT-2000B (manufactured by SC Organic Chemical) and XC-9206 (manufactured by King Industry).
- the ratio of the organometallic salt and / or the organometallic complex (C) is 0.01 to 8% by weight, more preferably 0.05 to 5% by weight, more preferably 0.05% by weight, based on the organopolysiloxane (A). Is 0.1 to 4% by weight. Further, it is particularly preferably 0.1 to 2% by weight.
- the curable resin composition of the present invention contains a light stabilizer (D).
- the light stabilizer (D) is preferably a compound represented by the following general formula (1).
- X 1 and X 2 are the same or different and each represents a hydrogen atom, an alkyl group having 1 to 50 carbon atoms, an aralkyl group, an aryl group, an aryl group having an alkyl group having 1 to 20 carbon atoms, an alkoxy group, or a structural formula (2)
- X 1 and X 2 is the structural formula (2)
- the structural formula (2) is bonded to the oxygen atom of the formula (1) at *.
- Y represents a hydrogen atom, an alkyl group having 1 to 50 carbon atoms, an aryl group, or an alkoxy group.
- Y methyl group Bis (1,2,2,6,6-pentamethylpiperidin-4-yl) carbonate having the structural formula (2) as X 1 and X 2
- Y Bis (2,2,6,6-tetramethyl-propoxypiperidin-4-yl) carbonate having structural formula (2) which is a propoxy group as X 1 and X 2
- structural formula (2) where Y undecyloxy group the bis and substituents X 1 and X 2 (1-undecane-2,2,6,6-tetramethylpiperidin-4-yl) carbonate
- Y structural formula is a methyl group and (2) and X 1 1,2,2,6,6-, wherein the tert-pentyloxy group is X 2 Examples include pentamethylpiperidin-4-yl tert-pentylcarbonoperoperate.
- the ratio of the light stabilizer (D) is 0.005 to 5% by weight, more preferably 0.01 to 4% by weight, and still more preferably 0.1 to 4% by weight with respect to the organopolysiloxane (A). 2% by weight.
- the ratio of the light stabilizer (D) is less than 0.005% by weight based on the organopolysiloxane (A)
- the effect of improving light resistance is insufficient.
- the cured resin is colored, which causes a decrease in illuminance.
- the light stabilizer (D) is used in combination with the organopolysiloxane (A), the polyvalent carboxylic acid (B), and the organometallic salt and / or organometallic complex (C). It can be significantly improved.
- a zinc salt and / or zinc complex as the organometallic salt and / or organometallic complex (C), and bis (1-undecanoxy-2,2,6,6-tetramethylpiperidine as the light stabilizer (D) -4-yl) carbonate is preferred, and these are preferably used in combination. This is because when used in the combination, it is excellent in light resistance and heat resistance, hardly colored by light or heat, and excellent in corrosion gas resistance.
- the light stabilizer (D) can be used in combination with other light stabilizers.
- the curable resin composition of the present invention is used for an optical material, particularly an optical semiconductor encapsulant, it is preferable to contain a phosphorus compound as an antioxidant as a particularly preferable component.
- the phosphorus compound is not particularly limited.
- 1,1,3-tris (2-methyl-4-ditridecyl phosphite-5-tert-butylphenyl) butane distearyl pentaerythritol diphosphite, bis (2,4-di-tert-butylphenyl) pentaerythritol diphosphite, bis (2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, phenylbisphenol A pentaerythritol diphosphite, Dicyclohexylpentaerythritol diphosphite, tris (diethylphenyl) phosphite, tris (di-isopropylphenyl) phosphite, tris (di-n-butylphenyl) phosphite, tris (2,4-di
- the commercially available phosphorus compounds are not particularly limited. For example, as Adeka, ADK STAB PEP-4C, ADK STAB PEP-8, ADK STAB PEP-24G, ADK STAB PEP-36, ADK STAB HP-10, ADK STAB 2112, ADK STAB 260 Adeka tab 522A, Adekas tab 1178, Adekas tab 1500, Adekas tab C, Adekas tab 135A, Adekas tab 3010, and Adekas tab TPP.
- the ratio of the phosphorus compound is 0.005 to 5% by weight, more preferably 0.01 to 4% by weight, and 0.1 to 2% by weight with respect to the organopolysiloxane (A).
- the curable resin composition of the present invention comprises an organopolysiloxane (A) as an epoxy resin, a polyvalent carboxylic acid (B) as a curing agent, an organometallic salt and / or organometallic complex (C) as an additive, and a light stabilizer ( D) is an essential component, and an acid anhydride as a curing agent and an antioxidant as a preferred optional component are included as optional components, but these can be used in combination with other epoxy resins, curing agents, and various additives.
- A organopolysiloxane
- B polyvalent carboxylic acid
- C organometallic salt and / or organometallic complex
- D light stabilizer
- an acid anhydride as a curing agent and an antioxidant as a preferred optional component are included as optional components, but these can be used in combination with other epoxy resins, curing agents, and various additives.
- the organopolysiloxane (A) can be used alone or in combination with other epoxy resins.
- the proportion of the organopolysiloxane (A) in the total epoxy resin is preferably 60% by weight or more, particularly preferably 70% by weight or more.
- Examples of other epoxy resins that can be used in combination with the organopolysiloxane (A) include novolac type epoxy resins, bisphenol A type epoxy resins, biphenyl type epoxy resins, triphenylmethane type epoxy resins, and phenol aralkyl type epoxy resins.
- bisphenol A bisphenol S, thiodiphenol, fluorene bisphenol, terpene diphenol, 4,4′-biphenol, 2,2′-biphenol, 3,3 ′, 5,5′-tetramethyl- [ 1,1′-biphenyl] -4,4′-diol, hydroquinone, resorcin, naphthalenediol, tris- (4-hydroxyphenyl) methane, 1,1,2,2-tetrakis (4-hydroxyphenyl) ethane, phenol (Phenol, alkyl-substituted phenol, naphthol, alkyl-substituted naphthol, dihydroxybenzene, dihydroxynaphthalene, etc.) and formaldehyde, acetaldehyde, benzaldehyde, p-hydroxybenzaldehyde, o-hydroxybenzaldehyde, p-hydroxyacetofu Non, o-hydroxy
- the curable resin composition of the present invention is mainly intended for use in optical applications. When used for optical applications, combined use with an alicyclic epoxy resin is preferred.
- an alicyclic epoxy resin a compound having an epoxycyclohexane structure in the skeleton is preferable, and an epoxy resin obtained by an oxidation reaction of a compound having a cyclohexane structure is particularly preferable.
- These alicyclic epoxy resins include esterification reaction of cyclohexene carboxylic acid with alcohols or esterification reaction of cyclohexene methanol with carboxylic acids (Tetrahedron vol.36 p.2409 (1980), Tetrahedron Letter p.4475 (1980) ), Or Tyschenco reaction of cyclohexene aldehyde (method described in Japanese Patent Application Laid-Open No. 2003-170059, Japanese Patent Application Laid-Open No. 2004-262871, etc.), and transesterification of cyclohexene carboxylic acid ester Examples thereof include an oxidized product of a compound that can be produced by a reaction (a method described in Japanese Patent Application Laid-Open No.
- the alcohol is not particularly limited as long as it is a compound having an alcoholic hydroxyl group, but ethylene glycol, propylene glycol, 1,3-propanediol, 1,2-butanediol, 1,4-butanediol, 1,5-pentane.
- Diols Diols, glycerol, trimethylolethane, trimethylolpropane, trimethylolbutane, triols such as 2-hydroxymethyl-1,4-butanediol, tetraols such as pentaerythritol, ditrimethylolpropane, etc.
- carboxylic acids include, but are not limited to, oxalic acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid, adipic acid, and cyclohexanedicarboxylic acid.
- epoxy resins include ERL-4221, UVR-6105, ERL-4299 (all trade names, all manufactured by Dow Chemical), Celoxide 2021P, Epolide GT401, EHPE3150, EHPE3150CE (all trade names, all Daicel) (Chemical Industry) and dicyclopentadiene diepoxide, and the like, but are not limited thereto (Reference: Review Epoxy Resin Basic Edition I p76-85). These may be used alone or in combination of two or more.
- the polycarboxylic acid (B) can be used alone or in combination with an acid anhydride, and further in combination with other curing agents.
- the proportion of the total amount of the polyvalent carboxylic acid compound (B) and the acid anhydride in the total curing agent is preferably 30% by weight or more, particularly preferably 40% by weight or more.
- the curing agent that can be used in combination include amine compounds, acid anhydride compounds, amide compounds, phenol compounds, and carboxylic acid compounds.
- curing agents that can be used include amines and polyamide compounds (diaminodiphenylmethane, diethylenetriamine, triethylenetetramine, diaminodiphenylsulfone, isophoronediamine, dicyandiamide, polyamide resin synthesized from ethylenediamine and dimer of linolenic acid, etc.) , Reaction product of acid anhydride and silicone alcohol (phthalic anhydride, trimellitic anhydride, pyromellitic anhydride, maleic anhydride, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride, methyl nadic anhydride, anhydrous Nadic acid, hexahydrophthalic anhydride, methylhexahydrophthalic anhydride, butanetetracarboxylic anhydride, bicyclo [2,2,1] heptane-2,3-dicarboxylic anhydride, methylbicyclo [2,2,2,
- halogenated bisphenols such as tetrabromobisphenol A, condensates of terpenes and phenols), and others (imidazole, trifluoroborane-amine complexes, guanidine derivatives, etc.) But this It is not limited to that. These may be used alone or in combination of two or more.
- the mixing ratio of the curing agent containing the organopolysiloxane (A) and the polyvalent carboxylic acid (B) as essential components is the epoxy group 1 of the organopolysiloxane (A). It is preferable to use a curing agent containing as an essential component a polyvalent carboxylic acid (B) having a functional group number of 0.7 to 1.2 equivalents, particularly preferably 0.75 to 1.10 equivalents based on equivalents. When less than 0.7 equivalent or more than 1.2 equivalent with respect to 1 equivalent of epoxy group, curing may be incomplete and good cured properties may not be obtained.
- other curing catalysts can be used in combination.
- Specific examples of the curing accelerator that can be used include 2-methylimidazole, 2-phenylimidazole, 2-undecylimidazole, 2-heptadecylimidazole, 2-phenyl-4-methylimidazole, and 1-benzyl-2-phenylimidazole.
- the curing catalyst is usually used in the range of 0.001 to 15 parts by weight with respect to 100 parts by weight of the epoxy resin.
- the curable resin composition of the present invention can be added with various additives and auxiliary materials as listed below.
- organopolysiloxane (A) and polyvalent carboxylic acid are organopolysiloxane (A) and polyvalent carboxylic acid. It can be added to either or both of (B), and can also be added after mixing organopolysiloxane (A) and polyvalent carboxylic acid (B).
- the curable resin composition of the present invention may contain a phosphorus-containing compound as a flame retardant component.
- the phosphorus-containing compound may be a reactive type or an additive type.
- Specific examples of phosphorus-containing compounds include trimethyl phosphate, triethyl phosphate, tricresyl phosphate, trixylylenyl phosphate, cresyl diphenyl phosphate, cresyl-2,6-dixylylenyl phosphate, 1,3-phenylenebis ( Phosphoric esters such as dixylylenyl phosphate), 1,4-phenylenebis (dixylylenyl phosphate), 4,4′-biphenyl (dixylylenyl phosphate); 9,10-dihydro-9-oxa Phosphanes such as -10-phosphaphenanthrene-10-oxide, 10 (2,5-dihydroxyphenyl) -10H-9-oxa-10-pho
- Phosphate esters, phosphanes or phosphorus-containing epoxy compounds are preferable, and 1,3-phenylenebis (dixylylenyl phosphate), 1,4-phenylenebis (dixylylene). Nyl phosphate), 4,4′-biphenyl (dixylylenyl phosphate) or phosphorus-containing epoxy compounds are particularly preferred.
- a binder resin can be blended with the curable resin composition of the present invention as required.
- the binder resin include butyral resins, acetal resins, acrylic resins, epoxy-nylon resins, NBR-phenol resins, epoxy-NBR resins, polyamide resins, polyimide resins, and silicone resins.
- the blending amount of the binder resin is preferably within a range that does not impair the flame retardancy and heat resistance of the cured product, and is usually 0.05 to 50 parts by weight, preferably 0.05 to 100 parts by weight of the curable resin component. Up to 20 parts by weight are used as needed.
- An inorganic filler can be added to the curable resin composition of the present invention as necessary.
- inorganic fillers include crystalline silica, fused silica, alumina, zircon, calcium silicate, calcium carbonate, silicon carbide, silicon nitride, boron nitride, zirconia, fosterite, steatite, spinel, titania, talc, and the like.
- the present invention is not limited to these.
- These fillers may be used alone or in combination of two or more. The content of these inorganic fillers is used in an amount of 0 to 95% by weight in the curable resin composition of the present invention.
- a silane coupling agent a release agent such as stearic acid, palmitic acid, zinc stearate, and calcium stearate, various compounding agents such as pigments, and various thermosetting resins are added to the curable resin composition of the present invention. can do.
- the particle size of the inorganic filler used is transparent by using a nano-order level filler. It is possible to supplement the mechanical strength and the like without hindering.
- a fluorescent substance can be added as needed.
- the phosphor has a function of forming white light by absorbing part of blue light emitted from a blue LED element and emitting wavelength-converted yellow light. After the phosphor is dispersed in advance in the curable resin composition, the optical semiconductor is sealed.
- fluorescent substance A conventionally well-known fluorescent substance can be used, For example, rare earth element aluminate, thio gallate, orthosilicate, etc. are illustrated.
- phosphors such as a YAG phosphor, a TAG phosphor, an orthosilicate phosphor, a thiogallate phosphor, and a sulfide phosphor can be mentioned, and YAlO 3 : Ce, Y 3 Al 5 O 12 : Ce, Y 4 Al 2 O 9: Ce, Y 2 O 2 S: Eu, Sr 5 (PO 4) 3 Cl: Eu, (SrEu) such as O ⁇ A l2 O 3 is exemplified.
- the particle size of the phosphor those having a particle size known in this field are used, and the average particle size is preferably 1 to 250 ⁇ m, particularly preferably 2 to 50 ⁇ m. When these phosphors are used, the addition amount thereof is 1 to 80 parts by weight, preferably 5 to 60 parts by weight, based on 100 parts by weight of the resin component.
- silica fine powder also called Aerosil or Aerosol
- a thixotropic agent can be added.
- silica fine powders examples include Aerosil® 50, Aerosil® 90, Aerosil® 130, Aerosil® 200, Aerosil® 300, Aerosil® 380, Aerosil® OX50, Aerosil® TT600, Aerosil® R972, Aerosil® R202, Aerosil® R202, Aerosil® R202, Aerosil® R202, Aerosil® R202, Aerosil® R805, RY200, RX200 (manufactured by Nippon Aerosil Co., Ltd.) and the like can be mentioned.
- the curable resin composition of the present invention can contain a phenolic compound as an antioxidant.
- the phenol compound is not particularly limited, and examples thereof include 2,6-di-tert-butyl-4-methylphenol and n-octadecyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate.
- phenolic compound Commercially available products can also be used as the phenolic compound.
- the commercially available phenolic compounds are not particularly limited. AO-30, ADK STAB AO-40, ADK STAB AO-50, ADK STAB AO-60, ADK STAB AO-70, ADK STAB AO-80, ADK STAB AO-90, ADK STAB AO-330, SUMITOMO CHEMICAL INDUSTRIES, SUMITIZER GA-80, SUMILIZER MDP-S, Sumili er BBM-S, Sumilizer GM, Sumilizer GS (F), and the like Sumilizer GP.
- TINUVIN 328, TINUVIN 234, TINUVIN 326, TINUVIN 120, TINUVIN 477, TINUVIN 479, CHIMASSORB 2020FDL, CHIMASSORB 119FL, and the like are manufactured by Ciba Specialty Chemicals.
- the amount of the compound is not particularly limited, but is in the range of 0.005 to 5.0% by weight with respect to the curable resin composition of the present invention.
- the curable resin composition of the present invention can be obtained by uniformly mixing each component.
- the curable resin composition of the present invention can be easily made into a cured product by a method similar to a conventionally known method.
- the resulting curable resin composition of the present invention is liquid, it is impregnated with potting, casting, or base material.
- the curable resin composition is poured into a mold, cast, and cured by heating.
- a method of molding by using a cast after casting or a transfer molding machine and further curing by heating can be mentioned.
- the curing temperature and time are 80 to 200 ° C. and 2 to 10 hours.
- a curing method it can be hardened at a high temperature at a stretch, but it is preferable to raise the temperature stepwise to advance the curing reaction.
- initial curing is performed at 80 to 150 ° C.
- post-curing is performed at 100 to 200 ° C.
- the temperature is preferably increased in 2 to 8 stages, more preferably 2 to 4 stages.
- the curable resin composition of the present invention is dissolved in a solvent such as toluene, xylene, acetone, methyl ethyl ketone, methyl isobutyl ketone, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, etc. to obtain a curable resin composition varnish, glass fiber,
- a prepreg obtained by impregnating a base material such as carbon fiber, polyester fiber, polyamide fiber, alumina fiber, paper, etc. and heat-dried is subjected to hot press molding to obtain a cured product of the curable resin composition of the present invention. can do.
- the solvent is used in an amount usually accounting for 10 to 70% by weight, preferably 15 to 70% by weight in the mixture of the curable resin composition of the present invention and the solvent.
- cured material which contains carbon fiber by a RTM system with a liquid composition can also be obtained.
- the curable resin composition of this invention can also be used as a film type sealing composition.
- a film-type resin composition first, the curable resin composition of the present invention is applied as a varnish on a release film, and after removing the solvent under heating, by performing B-stage, It is formed as a sheet-like adhesive.
- This sheet-like adhesive can be used as an interlayer insulating layer in a multilayer substrate or the like, and a batch film sealing of an optical semiconductor.
- the curable resin composition of the present invention is used as an optical semiconductor sealing material or die bond material will be described in detail.
- the curable resin composition of the present invention is used as a sealing material for an optical semiconductor such as a high-intensity white LED or a die bond material, an organopolysiloxane (A), a polyvalent carboxylic acid (B), an organic metal salt, and / Or thoroughly mix additives such as organometallic complex (C), light stabilizer (D), and other epoxy resins, curing agents, coupling agents, antioxidants, light stabilizers, etc. as necessary.
- the curable resin composition is prepared by the method described above and used as a sealing material or for both a die bond material and a sealing material.
- a mixing method a kneader, a three-roll, a universal mixer, a planetary mixer, a homomixer, a homodisper, a bead mill or the like is used to mix at room temperature or warm.
- Optical semiconductor elements such as high-intensity white LEDs are generally GaAs, GaP, GaAlAs, GaAsP, AlGa, InP, GaN, InN, AlN, InGaN laminated on a substrate of sapphire, spinel, SiC, Si, ZnO or the like.
- Such a semiconductor chip is bonded to a lead frame, a heat sink, or a package using an adhesive (die bond material).
- a wire such as a gold wire is connected to pass an electric current.
- the semiconductor chip is sealed with a sealing material such as an epoxy resin in order to protect it from heat and moisture and play a role of a lens.
- the curable resin composition of the present invention can be used as this sealing material or die bond material. From the viewpoint of the process, it is advantageous to use the curable resin composition of the present invention for both the die bond material and the sealing material.
- the curable resin composition of the present invention is applied by dispenser, potting, or screen printing, and then heated by placing the semiconductor chip thereon. Curing can be performed to bond the semiconductor chip.
- methods such as hot air circulation, infrared rays and high frequency can be used.
- the heating condition is preferably 80 to 230 ° C. for about 1 minute to 24 hours.
- post-curing is performed at 120 to 180 ° C. for 30 minutes to 10 hours. it can.
- a compression molding method or the like in which a semiconductor chip fixed on a substrate is immersed therein and heat-cured and then released from a mold is used.
- the injection method include dispenser, transfer molding, injection molding and the like.
- methods such as hot air circulation, infrared rays and high frequency can be used.
- the heating conditions are preferably 80 to 230 ° C. for about 1 minute to 24 hours.
- post-curing is performed at 120 to 180 ° C. for 30 minutes to 10 hours. it can.
- the curable resin composition of the present invention can be used for general applications in which curable resins such as epoxy resins are used.
- curable resins such as epoxy resins
- molding materials sheets, films, FRPs, etc.
- sealing materials sealing materials
- cyanate resin compositions for substrates acrylic ester resins as resist curing agents, other resins, etc. And the like.
- adhesives examples include civil engineering, architectural, automotive, general office and medical adhesives, as well as electronic material adhesives.
- adhesives for electronic materials include interlayer adhesives for multilayer substrates such as build-up substrates, die bonding agents, semiconductor adhesives such as underfills, BGA reinforcing underfills, anisotropic conductive films ( ACF) and an adhesive for mounting such as anisotropic conductive paste (ACP).
- sealing agents As sealing agents, potting, dipping, transfer mold sealing used for capacitors, transistors, diodes, light emitting diodes, ICs, LSIs, potting sealings used for COB, COF, TAB, etc. of ICs and LSIs, flip Examples include underfill used for chips and the like, and sealing (including reinforcing underfill) when mounting IC packages such as QFP, BGA, and CSP.
- the cured product obtained in the present invention can be used for various applications including optical component materials.
- the optical material refers to general materials used for applications that allow light such as visible light, infrared light, ultraviolet light, X-rays, and lasers to pass through the material. More specifically, in addition to LED sealing materials such as lamp type and SMD type, the following may be mentioned. It is a peripheral material for liquid crystal display devices such as a substrate material, a light guide plate, a prism sheet, a deflection plate, a retardation plate, a viewing angle correction film, an adhesive, and a film for a liquid crystal such as a polarizer protective film in the liquid crystal display field.
- color PDP plasma display
- antireflection films antireflection films
- optical correction films housing materials
- front glass protective films front glass replacement materials
- adhesives and LED displays that are expected as next-generation flat panel displays
- LED molding materials LED sealing materials, front glass protective films, front glass substitute materials, adhesives, and substrate materials for plasma addressed liquid crystal (PALC) displays, light guide plates, prism sheets, deflection plates , Phase difference plate, viewing angle correction film, adhesive, polarizer protective film, front glass protective film in organic EL (electroluminescence) display, front glass substitute material, adhesive, and various in field emission display (FED) Film substrate
- PLC plasma addressed liquid crystal
- VD video disc
- CD / CD-ROM CD-R / RW
- DVD-R / DVD-RAM MO / MD
- PD phase change disc
- disc substrate materials for optical cards Pickup lenses, protective films, sealing materials, adhesives and the like.
- optical equipment field they are still camera lens materials, finder prisms, target prisms, finder covers, and light receiving sensor parts. It is also a photographic lens and viewfinder for video cameras.
- optical components they are fiber materials, lenses, waveguides, element sealing materials, adhesives and the like around optical switches in optical communication systems.
- optical passive components and optical circuit components there are lenses, waveguides, LED sealing materials, CCD sealing materials, adhesives, and the like.
- OEIC optoelectronic integrated circuit
- automotive lamp reflectors In the field of automobiles and transport equipment, automotive lamp reflectors, bearing retainers, gear parts, anti-corrosion coatings, switch parts, headlamps, engine internal parts, electrical parts, various interior and exterior parts, drive engines, brake oil tanks, and automotive defenses Rusted steel plate, interior panel, interior material, wire harness for protection / bundling, fuel hose, automobile lamp, glass substitute.
- it is a multilayer glass for railway vehicles.
- they are toughness imparting agents for aircraft structural materials, engine peripheral members, protective / bundling wire harnesses, and corrosion-resistant coatings.
- it In the construction field, it is interior / processing materials, electrical covers, sheets, glass interlayers, glass substitutes, and solar cell peripheral materials. For agriculture, it is a house covering film.
- optical / electronic functional organic materials include organic EL element peripheral materials, organic photorefractive elements, optical amplification elements that are light-to-light conversion devices, optical arithmetic elements, substrate materials around organic solar cells, fiber materials, elements Sealing material, adhesive and the like.
- Synthesis example 1 As the first stage reaction, 114 parts of ⁇ - (3,4 epoxycyclohexyl) ethyltrimethoxysilane, 234 parts of silanol-terminated methylphenylsilicone oil having a weight average molecular weight of 1700 (GPC measured value) (measured using silanol equivalent 850, GPC) Was calculated as half the weight average molecular weight.), 18 parts of 0.5% potassium hydroxide (KOH) methanol solution (0.09 parts as KOH parts) was charged into the reaction vessel, and the bath temperature was set to 75 ° C. Then, the temperature was raised. After raising the temperature, the reaction was carried out under reflux for 8 hours.
- KOH potassium hydroxide
- Synthesis example 2 As the first stage reaction, 257 parts of ⁇ - (3,4 epoxycyclohexyl) ethyltrimethoxysilane, 505 parts of silanol-terminated methylphenyl silicone oil having a weight average molecular weight of 1700 (GPC measurement value) (silanol equivalent: 850, measured using GPC) was calculated as half the weight average molecular weight.), 40 parts of a 0.5% potassium hydroxide (KOH) methanol solution (0.2 parts as the KOH part) was charged into the reaction vessel, and the bath temperature was set to 75 ° C. Then, the temperature was raised. After raising the temperature, the reaction was carried out under reflux for 8 hours.
- KOH potassium hydroxide
- Synthesis example 3 A flask equipped with a stirrer, a reflux condenser, and a stirrer is purged with nitrogen, 20 parts of tricyclodecane dimethanol, methylhexahydrophthalic anhydride (manufactured by Shin Nippon Rika Co., Ltd., Ricacid MH or less, acid anhydride After adding 100 parts of the product (referred to as product H-1), the mixture was reacted at 40 ° C. for 3 hours and then heated and stirred at 70 ° C. for 1 hour (disappearance of tricyclodecane dimethanol (1 area% or less) was confirmed by GPC).
- Synthesis example 4 To a flask equipped with a stirrer, reflux condenser and stirrer, 20 parts of 2,4-diethylpentanediol and 100 parts of acid anhydride (H-1) were added while purging with nitrogen, and reacted at 40 ° C. for 3 hours. By heating and stirring at 70 ° C. for 1 hour (disappearance of 2,4-diethylpentanediol (1 area% or less) was confirmed by GPC). Polycarboxylic acid (B-2) and acid anhydride (H— 120 parts of a curing agent composition (T-2) containing 1) was obtained.
- the resulting colorless liquid resin had a GPC purity of 50 area% for polycarboxylic acid (B-2; the following formula (10)) and 50 area% for acid anhydride (H-1).
- the functional group equivalent was 201 g / eq. Met.
- Example 1 Comparative Examples 1 and 2 Organopolysiloxane compound (A-1) obtained in Synthesis Example 1 as an epoxy resin, and curing agent composition (T-1) obtained in Synthesis Example 3 (an organopolysiloxane (A) and a curing agent) as a curing agent
- the ratio of the composition (B) is 1: 0.8 in terms of functional group equivalent, zinc salt (zinc complex) as organometallic complex (XC-9206 or less, C-1) manufactured by Enomoto Kasei, and bis (1 -Undecanoxy-2,2,6,6-tetramethylpiperidin-4-yl) carbonate (Adeka ADEKA STAB LA-81 or less D-1), bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate (TINUVIN770DF manufactured by Ciba Japan, hereinafter referred to as D-2), bis (1-octyloxy-2,2,6,6-tetramethyl-4-piperidyl) (TIC manufactured by Ciba Japan
- Example 2 Comparative Examples 3, 4 Organopolysiloxane compound (A-2) obtained in Synthesis Example 2 as an epoxy resin, and curing agent composition (T-2) obtained in Synthesis Example 4 (an organopolysiloxane (A) and a curing agent) as a curing agent
- the ratio of the composition (B) is 1: 0.8 in terms of functional group equivalent, zinc salt (zinc complex) as an organometallic complex (18% octope Zn, hereinafter C-2), and bis ( 1-undecanoxy-2,2,6,6-tetramethylpiperidin-4-yl) carbonate (manufactured by ADEKA, Adekastab LA-81 or less D-1), bis (2,2,6,6-tetramethyl-4-piperidyl) Sebacate (TINUVIN770DF manufactured by Ciba Japan, hereinafter referred to as D-2), bis (1-octyloxy-2,2,6,6-tetramethyl-4-piperidyl) (Ciba Japan)
- Thermal durability transmission test The obtained curable resin composition was gently poured into a test piece mold, and the cast was cured under conditions of 150 ° C. ⁇ 3 hours after pre-curing at 120 ° C. ⁇ 1 hour. A cured product was obtained. About the obtained hardened
- LED lighting test Using the obtained curable resin composition, it was filled into a syringe and cast into a surface-mount type LED package having an outer diameter of 5 mm and mounted with a chip having a central emission wave of 465 nm using a precision discharge device. The cast product was put into a heating furnace and cured at 120 ° C. for 1 hour, further at 150 ° C. for 3 hours to produce an LED package. In the lighting test, a lighting test was performed at 60 mA which is twice the specified current of 30 mA (acceleration test). In the measurement, the illuminance retention before and after lighting for 1000 hours was measured using an integrating sphere, and the average value of three samples was recorded.
- Corrosion gas Ammonium sulfide 20% aqueous solution (turns black when sulfur component reacts with silver)
- Contact method A container of an ammonium sulfide aqueous solution and the LED package were mixed in a wide-mouth glass bottle, and the wide-mouth glass bottle was covered to bring the volatilized ammonium sulfide gas into contact with the LED package in a sealed state.
- Judgment of corrosion The time when the lead frame inside the LED package was discolored black (referred to as blackening) was observed, and it was determined that the longer the discoloration time, the better the corrosion gas resistance. The observation was taken out after 10 hours for confirmation, and the evaluation was indicated as ⁇ for those with no discoloration and ⁇ for those that were blackened.
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Abstract
Description
ところが、LED製品の発光波長の短波長化(主に青色発光をするLED製品で480nm以下)が進んだ結果、短波長の光の影響で前記封止材料がLEDチップ上で着色し最終的にはLED製品として、照度が低下してしまうという指摘がされている。
そこで、3,4-エポキシシクロヘキシルメチル-3′,4′エポキシシクロヘキシルカルボキシレートに代表される脂環式エポキシ樹脂は、芳香環を有するグリシジルエーテルタイプのエポキシ樹脂組成物と比較し透明性の点で優れていることから、LED封止材として積極的に検討がなされてきた。(特許文献1、2)
一般にシロキサン骨格を導入した樹脂はエポキシ樹脂よりも光に対して安定であることが知られているが、いまだ十分ではなく、さらなる改善が課題となっている。この課題を解決するための手段として、光安定剤を添加する方法が知られている(特許文献4)。しかし、光安定剤の添加により耐光性は改善するものの、LEDチップから発せられる熱などによって樹脂は劣化する。
(1)
オルガノポリシロキサン(A)と多価カルボン酸(B)、有機金属塩および/または有機金属錯体(C)、光安定剤(D)を含有する硬化性樹脂組成物、ただし、オルガノポリシロキサン(A)と多価カルボン酸(B)、光安定剤(D)は以下の条件を満たす。
オルガノポリシロキサン(A):少なくとも、その分子中にグリシジル基および/またはエポキシシクロヘキシル基を有するオルガノポリシロキサン
多価カルボン酸(B):少なくとも2つのカルボキシル基を有し、脂肪族炭化水素基を主骨格とする
光安定剤(D):構造式(1)で示される化合物
(ただし、X1,X2は水素原子、炭素数1~50のアルキル基、アラルキル基、アリール基、炭素数1~20のアルキル基を有するアリール基、アルコキシ基または構造式(2)であり、X1,X2の少なくとも一方は構造式(2)である。
(式(2)中、*印で構造式(2)は構造式(1)の酸素原子と結合する。また、Yは水素原子、炭素数1~50のアルキル基、アリール基、アルコキシ基を表す。))
(2)
構造式(2)のYが炭素数1~20のアルコキシ基である構造式(1)の化合物を含む前項(1)に記載の硬化性樹脂組成物、
(3)
有機金属塩および/または有機金属錯体(C)が燐酸エステル、燐酸の亜鉛塩、および/またはこれらの酸あるいはエステルを配位子として有する亜鉛錯体である前項(1)または(2)のいずれか一項に記載の硬化性樹脂組成物、
(4)
構造式(1)のX1、X2がともに構造式(2)であり、かつ、構造式(2)のYが -OC11H23 である前項(1)~(3)のいずれか一項に記載の硬化性樹脂組成物、
(5)
酸無水物を含有する前項(1)~(4)のいずれか一項に記載の硬化性樹脂組成物、
(6)
多価カルボン酸(B)が炭素数5以上の2~6官能の多価アルコールと飽和脂肪族環状酸無水物との反応により得られた化合物である前項(1)~(5)のいずれか一項に記載の硬化性樹脂組成物、
(7)
酸化防止剤を含有する前項(1)~(6)のいずれか一項に記載の硬化性樹脂組成物、
(8)
前項(1)~(7)のいずれか一項に記載の硬化性樹脂組成物を硬化してなる硬化物、
に関する。
本発明の硬化性樹脂組成物はオルガノポリシロキサン(A)と多価カルボン酸(B)、有機金属塩および/または有機金属錯体(C)、光安定剤(D)を含有する。
オルガノポリシロキサン(A)は、その分子中にグリシジル基および/またはエポキシシクロヘキシル基を有するオルガノポリシロキサンを使用する。
前記オルガノポリシロキサンは少なくとも、その分子中にグリシジル基および/またはエポキシシクロヘキシル基を有するオルガノポリシロキサンであることを特徴とし、一般にグリシジル基あるいはエポキシシクロヘキシル基を有するトリアルコキシシランを原料に用いるゾル-ゲル反応により得られる。
具体的には日本国特開2004-256609号公報、日本国特開2004-346144号公報、国際公開第2004/072150号、日本国特開2006-8747号公報、国際公開第2006/003990号、日本国特開2006-104248号公報、国際公開第2007/135909号、日本国特開2004-10849号公報、日本国日本国特開2004-359933号公報、国際公開第2005/100445号、日本国特開2008-174640号公報などに記載の三次元に広がる網の目状の構造を有したシルセスキオキサンタイプのオルガノポリシロキサンが挙げられる。
本発明において、構造については特に限定されないが、単純な三次元網目構造のシロキサン化合物では硬すぎるため、硬さを緩和する構造が望まれる。本発明においては特に鎖状のシリコーンセグメントと前述のシルセスキオキサン構造とを1分子中に有するブロック構造体が好ましい(以下、ブロック型シロキサン化合物(E)と称す)。
XSi(OR1)3 (3)
一般式(3)中のXとしては、グリシジル基および/またはエポキシシクロヘキシル基を含有する有機基であれば特に制限はない。例えば、β-グリシドキシエチル、γ-グリシドキシプロピル、γ-グリシドキシブチル等のグリシドオキシ基で置換された炭素数1~4のアルキル基、グリシジル基、β-(3,4-エポキシシクロヘキシル)エチル基、γ-(3,4-エポキシシクロヘキシル)プロピル基、β-(3,4-エポキシシクロヘプチル)エチル基、β-(3,4-エポキシシクロヘキシル)プロピル基、β-(3,4-エポキシシクロヘキシル)ブチル基、β-(3,4-エポキシシクロヘキシル)ペンチル基等のオキシラン基を持ったシクロヘキシル基で置換された炭素数1~5のアルキル基が挙げられる。これらの中で、グリシドオキシ基で置換された炭素数1~3のアルキル基、エポキシ基を有するシクロヘキシル基で置換された炭素数1~3のアルキル基、例えば、β-グリシドキシエチル基、γ-グリシドキシプロピル基、β-(3,4-エポキシシクロヘキシル)エチル基が好ましく、特にβ-(3,4-エポキシシクロヘキシル)エチル基が好ましい。
一般式(4)の式中、複数存在するR2は互いに同一であっても異なっていてもよく、炭素数1~10のアルキル基、炭素数6~14のアリール基、炭素数2~10のアルケニル基を示す。また、mは繰り返し単位数を示す。
炭素数1~10のアルキル基としては、炭素数1~10の直鎖状、分岐状もしくは環状のアルキル基が挙げられ、例えば、メチル基、エチル基、n-プロピル基、i-プロピル基、n-ブチル基、i-ブチル基、sec-ブチル基、t-ブチル基、n-ペンチル基、i-ペンチル基、n-ヘキシル基、シクロペンチル基、シクロヘキシル基、オクチル基、2-エチルヘキシル基、ノニル基、デシル基等を挙げることができる。これらの中で、耐光性を考慮すると、メチル基、エチル基、シクロヘキシル基が好ましい。
炭素数6~14のアリール基としては、例えば、フェニル基、o-トリル基、m-トリル基、p-トリル基、キシリル基等を挙げることができる。
炭素数2~10のアルケニル基としては、ビニル基、1-メチルビニル基、アリル基、プロペニル基、ブテニル基、ペンテニル基、ヘキセニル基等のアルケニル基等を挙げることができる。
R2は耐光性、耐熱性の観点から、メチル基、フェニル基、シクロヘキシル基、n-プロピル基が好ましく、特にメチル基、フェニル基が好ましい。
GPCの各種条件
メーカー:島津製作所
カラム:ガードカラム SHODEX GPC LF-G LF-804(3本)
流速:1.0ml/min.
カラム温度:40℃
使用溶剤:THF(テトラヒドロフラン)
検出器:RI(示差屈折検出器)
R3Si(OR4)3 (5)
一般式(5)中のR3は、メチル基又はフェニル基を示す。
当量値が200を超えるとブロック型シロキサン化合物(E)を用いた硬化物が硬くなりすぎて目的の低弾性率特性が低下する。
製造工程(1):シラノール末端シリコーンオイルとアルコキシ基を有するケイ素化合物の脱アルコール縮合を行なう工程
製造工程(2):水を添加しアルコキシ基を有するケイ素化合物のアルコキシ基同士の加水分解縮合を行なう工程
製造工程(1)(2)は各工程を経由すれば、どのような順に反応を行ってもかまわない。
<製造方法(イ)>
まず、製造工程(1)として末端にシラノール基を有するシリコーンオイル(b)とアルコキシ基を有するケイ素化合物であるアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))との脱アルコール縮合反応により、シリコーンオイル末端をアルコキシシラン変性することにより、アルコキシシラン変性体(d)を得る工程を行う。
次いで製造工程(2)としてアルコキシ基を有するケイ素化合物であるアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))、および製造工程(1)で得られたシリコーンオイルのアルコキシシラン変性体(d)に水を添加してアルコキシ基同士の加水分解縮合反応を行う工程を経ることによりブロック型シロキサン化合物(E)を製造する方法。
<製造方法(ロ)>
まず、製造工程(2)としてアルコキシ基を有するケイ素化合物であるアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))の水の添加によるアルコキシ基同士の加水分解縮合反応を行うことで分子内にアルコキシ基を有するシルセスキオキサン(e)を得る工程を行う。
次いで製造工程(1)として末端にシラノール基を有するシリコーンオイル(b)とシルセスキオキサン(e)との反応により、シルセスキオキサン構造に残存するアルコキシ基とシラノール基の脱アルコール縮合反応させる工程を経ることにより、ブロック型シロキサン化合物(E)を製造する方法。
<製造方法(ハ)>
まず、製造工程(1)として末端にシラノール基を有するシリコーンオイル(b)とアルコキシ基を有するケイ素化合物であるアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))との脱アルコール縮合反応により、シリコーンオイル末端をアルコキシシラン変性することによりアルコキシシラン変性体(d)とした後、系内に水を添加し、製造工程(2)として残存するアルコキシシラン(a)(アルコキシシラン(c))、およびアルコキシシラン変性体(d)のアルコキシ基同士の加水分解縮合反応をワンポットで行うことによりブロック型シロキサン化合物(E)を製造する方法。
以下、さらに具体的に製造方法(ハ)について述べる。
ワンポットで反応させる場合、前述の製造方法(ハ)と逆の順番、すなわち、(ロ)の如く製造工程(2)の後に製造工程(1)を行なうと、製造工程(2)で形成されたアルコキシ基を有するシルセスキオキサンオリゴマーとシリコーンオイル(b)とが、相溶せず、後の製造工程(1)において脱アルコール縮合重合が進行せず、未反応のシリコーンオイルが残留する可能性が高い。一方で、製造方法(ハ)のように製造工程(1)の後にワンポットで製造工程(2)を行なう方法を用いれば、シリコーンオイル(b)とアルコキシシラン(a)やアルコキシシラン(c)との相溶性比較的高いため、前述のように相溶せずに反応が進行しない、という問題は回避できる。さらにはアルコキシシラン同士で縮合反応を起こしていない低分子アルコキシシランが、シラノール基に対して多量に存在することになるため、反応性の観点からも好ましい。ワンポットで行なう場合の製造工程(1)を第1段階反応、製造工程(2)を第2段階反応とすると、まず第1段階反応(製造工程(1))において、シリコーンオイル(b)とアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))の脱アルコール縮合を行ない、シリコーンオイルの末端をアルコキシシリル変性させ、アルコキシシラン変性体(d)を得る。第1段反応においては水を添加していないので、アルコキシ基同士の加水分解縮合は起こらず、シラノール基1当量に対して、アルコキシ基を3当量以上用いて反応させた場合、アルコキシシラン変性体(d)は下記式(6)で示されるような構造で存在していると考えられる。
(I)系中に残存しているアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))のアルコキシ基同士の縮合反応。
(II)第1段階反応で得られたアルコキシシラン変性体(d)とアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))のアルコキシ基同士の縮合反応。
(III)第1段階反応で得られたアルコキシシラン変性体(d)と(I)で生成したアルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))の部分縮合物のアルコキシ基同士の縮合反応。
第2段階反応においては上記反応が複合して起こり、シルセスキオキサンセグメントの形成と、さらにシリコーンオイル由来の鎖状シリコーンセグメントとの縮合が同時に行なわれる。
触媒の添加方法は、直接添加するか、可溶性の溶剤等に溶解させた状態で使用する。その中でもメタノール、エタノール、プロパノール、ブタノール等のアルコール類に触媒をあらかじめ溶解させた状態で添加するのが好ましい。この際に、水などを用いた水溶液として添加することは、前記したように、アルコキシシラン(a)(必要に応じて添加されるアルコキシシラン(c))の縮合を一方的に進行させ、それにより生成したシルセスキオキサンオリゴマーと、シリコーンオイル(b)とが相溶せず白濁する可能性がある。
中和反応には酸性または塩基性を示す化合物であれば使用する事ができる。酸性を示す化合物の例としては、塩酸、硫酸、硝酸等の無機酸や蟻酸、酢酸、蓚酸等の有機酸が挙げられる。また、塩基性を示す化合物の例としては、水酸化ナトリウム、水酸化カリウム、水酸化リチウム、水酸化セシウムのようなアルカリ金属水酸化物、炭酸ナトリウム、炭酸カリウム、炭酸水素ナトリウム、炭酸水素カリウムのようなアルカリ金属炭酸塩、燐酸、燐酸二水素ナトリウム、燐酸水素二ナトリウム、燐酸トリナトリウム、ポリ燐酸、トリポリ燐酸ナトリウムのようなリン酸塩類等の無機塩基、アンモニア、トリエチルアミン、ジエチレントリアミン、n-ブチルアミン、ジメチルアミノエタノール、トリエタノールアミン、テトラメチルアンモニウムハイドロオキサイド等の有機塩基を使用することができる。これらの中でも、特に生成物からの除去が容易である点で無機塩基もしくは無機酸が好ましく、さらに好ましくは中性付近へのpHの調整がより容易である燐酸塩類などである。
活性白土としては、例えば、東新化成社製として、活性白土SA35、SA1、T、R-15、E、ニッカナイトG-36、G-153、G-168が、水沢化学工業社製として、ガレオンアース、ミズカエースなどが挙げられる。活性炭としては、例えば、味の素ファインテクノ社製として、CL-H、Y-10S、Y-10SFがフタムラ化学社製として、S、Y、FC、DP、SA1000、K、A、KA、M、CW130BR、CW130AR、GM130Aなどが挙げられる。ゼオライトとしては、例えば、ユニオン昭和社製として、モレキュラーシーブ3A、4A、5A、13Xなどが挙げられる。合成吸着剤としては、例えば、協和化学社製として、キョーワード100、200、300、400、500、600、700、1000、2000や、ローム・アンド・ハース社製として、アンバーリスト15JWET、15DRY、16WET、31WET、A21、アンバーライトIRA400JCl、IRA403BLCl、IRA404JClや、ダウケミカル社製、ダウエックス66、HCR-S、HCR-W2、MAC-3などが挙げられる。
吸着剤を反応液に加え、攪拌、加熱等の処理を行い、触媒を吸着した後に、吸着剤をろ過、さらには残渣を水洗することによって、触媒、吸着剤を除くことができる。
重量平均分子量はGPC(ゲルパーミエーションクロマトグラフィー)を用いて下記条件下測定されたポリスチレン換算の重量平均分子量(Mw)である。
GPCの各種条件
メーカー:島津製作所
カラム:ガードカラム SHODEX GPC LF-G LF-804(3本)
流速:1.0ml/min.
カラム温度:40℃
使用溶剤:THF(テトラヒドロフラン)
検出器:RI(示差屈折検出器)
存在するケイ素原子の割合は、ブロック型シロキサン化合物(E)の1H NMR、29Si NMR、元素分析等によって求めることができる。
多価カルボン酸(B)としては、特に2~6官能のカルボン酸が好ましい。多価カルボン酸(B)は炭素数が少ないと固形化の影響が強く、封止材として作業性が低下するため、炭素数5以上の2~6官能の多価アルコールと酸無水物との反応により得られた化合物とであることが好ましい。炭素数が5以上であれば封止材として良好な作業性を確保することができる。さらに、耐久性の観点から耐熱性を向上させるためにも上記酸無水物は飽和脂肪族環状酸無水物であるポリカルボン酸が好ましい。
特に好ましいアルコール類としては炭素数が5以上のアルコールであり、特に1,6-ヘキサンジオール、1,4-シクロヘキサンジメタノール、1,3-シクロヘキサンジメタノール、1,2-シクロヘキサンジメタノール、2,4-ジエチルペンタンジオール、2-エチル-2-ブチル-1,3-プロパンジオール、ネオペンチルグリコール、トリシクロデカンジメタノール、ノルボルネンジオールなどの化合物が好ましく、中でも耐熱性、耐光性を付与し、高い照度保持率を維持させるという観点から、2-エチル-2-ブチル-1,3-プロパンジオール、ネオペンチルグリコール、2,4-ジエチルペンタンジオール、1,4-シクロヘキサンジメタノール、トリシクロデカンジメタノール、ノルボルネンジオールなどの分岐鎖状構造や環状構造を有するアルコール類がより好ましい。
酸無水物としては特にメチルテトラヒドロ無水フタル酸、無水メチルナジック酸、無水ナジック酸、ヘキサヒドロ無水フタル酸、メチルヘキサヒドロ無水フタル酸、ブタンテトラカルボン酸無水物、ビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、メチルビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物などが好ましく、中でも透明性が高いためメチルヘキサヒドロ無水フタル酸、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物が好ましい。
付加反応の条件としては特に指定はないが、具体的な反応条件の1つとしては酸無水物、多価アルコールを無触媒、無溶剤の条件下、40~150℃で反応させ加熱し、反応終了後、そのまま取り出すという手法である。ただし、本反応条件に限定されない。
(式中、複数存在するQは、水素原子、メチル基、カルボキシル基の少なくとも1種以上を表す。Pは前述の多価アルコール由来の炭素数2~20の鎖状、分岐状、環状の脂肪族基である。mは、多価アルコールの官能基数であり、好ましくは2~6の整数である。)で表される化合物が好ましい。
酸無水物としては具体的には無水フタル酸、無水トリメリット酸、無水ピロメリット酸、無水マレイン酸、テトラヒドロ無水フタル酸、メチルテトラヒドロ無水フタル酸、無水メチルナジック酸、無水ナジック酸、ヘキサヒドロ無水フタル酸、メチルヘキサヒドロ無水フタル酸、ブタンテトラカルボン酸無水物、ビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、メチルビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物、などの酸無水物が挙げられる。
特にメチルテトラヒドロ無水フタル酸、無水メチルナジック酸、無水ナジック酸、ヘキサヒドロ無水フタル酸、メチルヘキサヒドロ無水フタル酸、ブタンテトラカルボン酸無水物、ビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、メチルビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物などが好ましい。
特に好ましくは下記式(8)
(式中、存在するZは、水素原子、メチル基、カルボキシル基の少なくとも1種以上を表す。)で表されるヘキサヒドロ無水フタル酸、メチルヘキサヒドロ無水フタル酸、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物が好ましく、中でも透明性が高いためメチルヘキサヒドロ無水フタル酸、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物が好ましい。
W1/(W1+W2)=0.05~0.65
ただし、W1は多価カルボン酸(B)の配合重量部、W2は酸無水物の配合重量部を示す。W1/(W1+W2)の範囲として、好ましくは、0.05~0.65、さらに好ましくは0.10~0.65、特に好ましくは0.3~0.6である。0.05を下回ると、硬化時に酸無水物の揮発が多くなる傾向が強く、好ましくない。0.65を超えると高い粘度となり、取り扱いが難しくなる。酸無水物を含有させない(少量残存する場合は除く)場合、その形状は固形もしくは固形に近い状態、もしくは結晶となるため、問題はない。
多価カルボン酸(B)と酸無水物を併用する場合、多価カルボン酸(B)の製造時に過剰の酸無水物の中で製造し、多価カルボン酸(B)と酸無水物の混合物を作るという手法も操作の簡便性の面から好ましい。
有機金属塩および/または有機金属錯体(C)の金属としてはアルミニウム、マンガン、鉄、コバルト、ニッケル、銅、亜鉛、ジルコニウム、スズ、鉛等がある。
前記有機金属塩および/または有機金属錯体(C)としては、例えば、2-エチルヘキサン酸アルミニウム、2-エチルヘキサン酸マンガン、2-エチルヘキサン酸鉄、2-エチルヘキサン酸コバルト、2-エチルヘキサン酸ニッケル、2-エチルヘキサン酸銅、2-エチルヘキサン酸亜鉛、2-エチルヘキサン酸ジルコニウム、2-エチルヘキサン酸スズ、2-エチルヘキサン酸鉛、ナフテン酸アルミニウム、ナフテン酸マンガン、ナフテン酸鉄、ナフテン酸コバルト、ナフテン酸ニッケル、ナフテン酸銅、ナフテン酸亜鉛、ナフテン酸ジルコニウム、ナフテン酸スズ、ナフテン酸鉛、ステアリン酸アルミニウム、ステアリン酸マンガン、ステアリン酸鉄、ステアリン酸コバルト、ステアリン酸ニッケル、ステアリン酸銅、ステアリン酸亜鉛、ステアリン酸ジルコニウム、ステアリン酸スズ、ステアリン酸鉛、ウンデシレン酸亜鉛、ラウリン酸亜鉛、ペヘン酸亜鉛、12-ヒドロキシステアリン酸亜鉛、モンタン酸亜鉛、ミリスチン酸亜鉛、パルミチン酸亜鉛、ナフテン酸亜鉛、ヘキソエート亜鉛、オクチル酸亜鉛、アルミニウム-アセチルアセトン錯体、マンガン-アセチルアセトン錯体、鉄-アセチルアセトン錯体、コバルト-アセチルアセトン錯体、ニッケル-アセチルアセトン錯体、銅-アセチルアセトン錯体、亜鉛-アセチルアセトン錯体、リン酸(2-エチルヘキシル)の亜鉛錯体、ジルコニウム-アセチルアセトン錯体、スズ-アセチルアセトン錯体、鉛-アセチルアセトン錯体等が挙げられる。
ここで、耐腐食ガス性を与える観点から、亜鉛塩および/または亜鉛錯体が好ましく、具体的には、2-エチルヘキサン酸亜鉛、リン酸(2-エチルヘキシル)の亜鉛錯体及び/またはその塩、ステアリン酸亜鉛、ウンデシレン酸亜鉛、ラウリン酸亜鉛、ペヘン酸亜鉛、12-ヒドロキシステアリン酸亜鉛、モンタン酸亜鉛、ミリスチン酸亜鉛、パルミチン酸亜鉛、ナフテン酸亜鉛、ヘキソエート亜鉛、オクチル酸亜鉛が好ましい。
また、なかでも相溶性の観点から、2-エチルヘキサン酸亜鉛、リン酸(2-エチルヘキシル)の亜鉛錯体及び/またはその塩、ステアリン酸亜鉛、ウンデシレン酸亜鉛がより好ましく、透明性を考慮すると、2-エチルヘキサン酸亜鉛、リン酸(2-エチルヘキシル)の亜鉛錯体及び/またはその塩が特に好ましい。
このようなカルボン酸亜鉛体として、市販品としては、Zn-St、Zn-ST 602、Zn-St NZ、ZS-3、ZS-6、ZS-8、ZS-7、ZS-10、ZS-5、ZS-14、ZS-16(日東化成工業製)、XK-614(キングインダストリー製)、18%オクトープZn、12%オクトープZn、8%オクトープZn(ホープ製薬製)、リン酸エステルおよび/またはリン酸亜鉛体として、LBT-2000B(SC有機化学製)、XC-9206(キングインダストリー製)が挙げられる。
ただし、X1,X2は同一もしくは異なり水素原子、炭素数1~50のアルキル基、アラルキル基、アリール基、炭素数1~20のアルキル基を有するアリール基、アルコキシ基または構造式(2)であり、X1,X2の少なくとも一方は構造式(2)である
前記式中、*印で構造式(2)は式(1)の酸素原子と結合する。また、Yは水素原子、炭素数1~50のアルキル基、アリール基、アルコキシ基を表す。
一般式(1)で表される化合物の好適な具体例としては、Y=水素原子である構造式(2)をX1およびX2とするビス(2,2,6,6-テトラメチルピペリジン-4-イル)カーボネート、Y=メチル基である構造式(2)をX1およびX2とするビス(1,2,2,6,6-ペンタメチルピペリジン-4-イル)カーボネート、Y=プロポキシ基である構造式(2)をX1およびX2とするビス(2,2,6,6-テトラメチル-プロポキシピペリジン-4-イル)カーボネート、Y=ウンデシロキシ基である構造式(2)を置換基X1およびX2とするビス(1-ウンデカンオキシ-2,2,6,6-テトラメチルピペリジン-4-イル)カーボネート、Y=メチル基である構造式(2)をX1とし、tert-ペンチルオキシ基をX2とする1,2,2,6,6-ペンタメチルピペリジン-4-イルtert-ペンチルカルボノペルオキシアート等がある。特に好ましい化合物として、Y=ウンデシロキシ基である構造式(2)を置換基X1およびX2とするビス(1-ウンデカンオキシ-2,2,6,6-テトラメチルピペリジン-4-イル)カーボネートが挙げられる。
光安定剤(D)の比率がオルガノポリシロキサン(A)に対して0.005重量%未満では、耐光性の改善効果が不十分である。一方、5重量%より多いと、樹脂硬化物が着色し、照度の低下を招くため好ましくない。
これら脂環式エポキシ樹脂としては、シクロヘキセンカルボン酸とアルコール類とのエステル化反応あるいはシクロヘキセンメタノールとカルボン酸類とのエステル化反応(Tetrahedron vol.36 p.2409 (1980)、Tetrahedron Letter p.4475 (1980)等に記載の手法)、あるいはシクロヘキセンアルデヒドのティシェンコ反応(日本国特開2003-170059号公報、日本国特開2004-262871号公報等に記載の手法)、さらにはシクロヘキセンカルボン酸エステルのエステル交換反応(日本国特開2006-052187号公報等に記載の手法)によって製造できる化合物を酸化した物などが挙げられる。
アルコール類としては、アルコール性水酸基を有する化合物であれば特に限定されないがエチレングリコール、プロピレングリコール、1,3-プロパンジオール、1,2-ブタンジオール、1,4-ブタンジオール、1,5-ペンタンジオール、1,6-ヘキサンジオール、シクロヘキサンジメタノール、2,4-ジエチルペンタンジオール、2-エチル-2-ブチル-1,3-プロパンジオール、ネオペンチルグリコール、トリシクロデカンジメタノール、ノルボルネンジオールなどのジオール類、グリセリン、トリメチロールエタン、トリメチロールプロパン、トリメチロールブタン、2-ヒドロキシメチル-1,4-ブタンジオールなどのトリオール類、ペンタエリスリトール、ジトリメチロールプロパンなどのテトラオール類などが挙げられる。またカルボン酸類としてはシュウ酸、マレイン酸、フマル酸、フタル酸、イソフタル酸、アジピン酸、シクロヘキサンジカルボン酸などが挙げられるがこれに限らない。
これらエポキシ樹脂の具体例としては、ERL-4221、UVR-6105、ERL-4299(全て商品名、いずれもダウ・ケミカル製)、セロキサイド2021P、エポリードGT401、EHPE3150、EHPE3150CE(全て商品名、いずれもダイセル化学工業製)及びジシクロペンタジエンジエポキシドなどが挙げられるがこれらに限定されるものではない(参考文献:総説エポキシ樹脂 基礎編I p76-85)。
これらは単独で用いてもよく、2種以上併用してもよい。
併用しうる硬化剤としては、例えばアミン系化合物、酸無水物系化合物、アミド系化合物、フェノール系化合物、カルボン酸系化合物などが挙げられる。用いうる硬化剤の具体例としては、アミン類やポリアミド化合物(ジアミノジフェニルメタン、ジエチレントリアミン、トリエチレンテトラミン、ジアミノジフェニルスルホン、イソホロンジアミン、ジシアンジアミド、リノレン酸の2量体とエチレンジアミンより合成されるポリアミド樹脂など)、酸無水物とシリコーン系のアルコール類との反応物(無水フタル酸、無水トリメリット酸、無水ピロメリット酸、無水マレイン酸、テトラヒドロ無水フタル酸、メチルテトラヒドロ無水フタル酸、無水メチルナジック酸、無水ナジック酸、ヘキサヒドロ無水フタル酸、メチルヘキサヒドロ無水フタル酸、ブタンテトラカルボン酸無水物、ビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、メチルビシクロ[2,2,1]ヘプタン-2,3-ジカルボン酸無水物、シクロヘキサン-1,2,4-トリカルボン酸-1,2-無水物、などの酸無水物とカルビノール変性シリコーンなどのシリコーン系アルコール類との反応物など)、多価フェノール類(ビスフェノールA、ビスフェノールF、ビスフェノールS、フルオレンビスフェノール、テルペンジフェノール、4,4’-ビフェノール、2,2’-ビフェノール、3,3’,5,5’-テトラメチル-[1,1’-ビフェニル]-4,4’-ジオール、ハイドロキノン、レゾルシン、ナフタレンジオール、トリス-(4-ヒドロキシフェニル)メタン、1,1,2,2-テトラキス(4-ヒドロキシフェニル)エタン、フェノール類(フェノール、アルキル置換フェノール、ナフトール、アルキル置換ナフトール、ジヒドロキシベンゼン、ジヒドロキシナフタレン等)とホルムアルデヒド、アセトアルデヒド、ベンズアルデヒド、p-ヒドロキシベンズアルデヒド、o-ヒドロキシベンズアルデヒド、p-ヒドロキシアセトフェノン、o-ヒドロキシアセトフェノン、ジシクロペンタジエン、フルフラール、4,4’-ビス(クロロメチル)-1,1’-ビフェニル、4,4’-ビス(メトキシメチル)-1,1’-ビフェニル、1,4’-ビス(クロロメチル)ベンゼン、1,4’-ビス(メトキシメチル)ベンゼン等との重縮合物及びこれらの変性物、テトラブロモビスフェノールA等のハロゲン化ビスフェノール類、テルペンとフェノール類の縮合物)、その他(イミダゾール、トリフルオロボラン-アミン錯体、グアニジン誘導体、など)などが挙げられるが、これらに限定されるものではない。これらは単独で用いてもよく、2種以上を用いてもよい。
次に本発明の硬化性樹脂組成物を光半導体の封止材又はダイボンド材として用いる場合について詳細に説明する。
注入方法としては、ディスペンサー、トランスファー成形、射出成形等が挙げられる。
加熱は、熱風循環式、赤外線、高周波等の方法が使用できる。
加熱条件は例えば80~230℃で1分~24時間程度が好ましい。加熱硬化の際に発生する内部応力を低減する目的で、例えば80~120℃、30分~5時間予備硬化させた後に、120~180℃、30分~10時間の条件で後硬化させることができる。
(1)分子量:ゲルパーミエーションクロマトグラフィー(GPC)法により、下記条件下測定されたポリスチレン換算、重量平均分子量を算出した。
GPCの各種条件
メーカー:島津製作所カラム:ガード
カラム SHODEX GPC LF-G LF-804(3本)
流速:1.0ml/min.
カラム温度:40℃
使用溶剤:THF(テトラヒドロフラン)
検出器:RI(示差屈折検出器)
(2)エポキシ当量:JIS K-7236に記載の方法で測定。
(3)粘度:東機産業株式会社製E型粘度計(TV-20)を用いて25℃で測定。
以下、合成例、実施例により本発明を更に詳細に説明する。なお、合成例、実施例において「部」は重量部を、「%」は重量%をそれぞれ意味する。
第1段階反応として、β-(3,4エポキシシクロヘキシル)エチルトリメトキシシラン114部、重量平均分子量1700(GPC測定値)のシラノール末端メチルフェニルシリコーンオイル234部(シラノール当量850、GPCを用いて測定した重量平均分子量の半分として算出した。)、0.5%水酸化カリウム(KOH)メタノール溶液18部(KOH部数としては、0.09部)を反応容器に仕込み、バス温度を75℃に設定し、昇温した。昇温後、還流下にて8時間反応させた。
第2段階反応として、メタノールを305部追加後、50%蒸留水メタノール溶液86.4部を60分かけて滴下し、還流下75℃にて8時間反応させた。反応終了後、5%リン酸2水素ナトリウム水溶液で中和後、80℃でメタノールの蒸留回収を行った。メチルイソブチルケトン(MIBK)380部を添加し、水洗を3回繰り返した。次いで有機相を減圧下、100℃で溶媒を除去することにより反応性官能基を有するオルガノポリシロキサン化合物(A-1)303部を得た。得られた化合物のエポキシ当量は677g/eq、重量平均分子量は2200、外観は無色透明であった。
第1段階反応として、β-(3,4エポキシシクロヘキシル)エチルトリメトキシシラン257部、重量平均分子量1700(GPC測定値)のシラノール末端メチルフェニルシリコーンオイル505部(シラノール当量850、GPCを用いて測定した重量平均分子量の半分として算出した。)、0.5%水酸化カリウム(KOH)メタノール溶液40部(KOH部数としては、0.2部)を反応容器に仕込み、バス温度を75℃に設定し、昇温した。昇温後、還流下にて8時間反応させた。
第2段階反応として、メタノールを510部追加後、50%蒸留水メタノール溶液130部を60分かけて滴下し、還流下75℃にて8時間反応させた。反応終了後、5%リン酸2水素ナトリウム水溶液で中和後、80℃でメタノールの蒸留回収を行った。メチルイソブチルケトン(MIBK)704部を添加し、水洗を3回繰り返した。次いで有機相を減圧下、100℃で溶媒を除去することにより反応性官能基を有するオルガノポリシロキサン化合物(A-2)663部を得た。得られた化合物のエポキシ当量は659g/eq、重量平均分子量は2370、外観は無色透明であった。
撹拌機、還流冷却管、撹拌装置を備えたフラスコに、窒素パージを施しながらトリシクロデカンジメタノール20部、メチルヘキサヒドロフタル酸無水物(新日本理化(株)製、リカシッドMH 以下、酸無水物H-1と称す)100部を加え、40℃で3時間反応後70℃で1時間加熱撹拌を行うことで(GPCによりトリシクロデカンジメタノールの消失(1面積%以下)を確認した。)多価カルボン酸(B-1)と酸無水物(H-1) を含有する硬化剤組成物(T-1)が120部得られた。得られた無色の液状樹脂であり、GPCによる純度は多価カルボン酸(B-1;下記式(9))を55面積%、メチルヘキサヒドロフタル酸無水物が45面積%であった。また、官能基当量は201g/eq.であった。
式(9)
撹拌機、還流冷却管、撹拌装置を備えたフラスコに、窒素パージを施しながら2,4-ジエチルペンタンジオール20部、酸無水物(H-1)100部を加え、40℃で3時間反応後70℃で1時間加熱撹拌を行うことで(GPCにより2,4-ジエチルペンタンジオールの消失(1面積%以下)を確認した。)多価カルボン酸(B-2)と酸無水物(H-1)を含有する硬化剤組成物(T-2)が120部得られた。得られた無色の液状樹脂であり、GPCによる純度は多価カルボン酸(B-2;下記式(10))を50面積%、酸無水物(H-1)が50面積%であった。また、官能基当量は201g/eq.であった。
式(10)
エポキシ樹脂として合成例1で得られたオルガノポリシロキサン化合物(A-1)、硬化剤として、合成例3で得られた硬化剤組成物(T-1)(オルガノポリシロキサン(A)と硬化剤組成物(B)の比率は官能基当量で1:0.8)、有機金属錯体として亜鉛塩(亜鉛錯体)(楠本化成製 XC-9206 以下、C-1)、光安定剤としてビス(1-ウンデカンオキシ-2,2,6,6-テトラメチルピペリジン-4-イル)カーボネート(ADEKA製 アデカスタブLA-81 以下 D-1)、ビス(2,2,6,6-テトラメチルー4-ピペリジル)セバケート(チバジャパン製 TINUVIN770DF 以下、D-2と称す。)、ビス(1-オクチルオキシ-2,2,6,6-テトラメチル-4-ピペリジル)(チバジャパン製 TINUVIN123 以下、D-3)、酸化防止剤のリン系化合物として、4,4´-ブチリデンビス(3-メチル-6-tert-ブチルフェニル-ジ-トリデシルホスファイト)(ADEKA製 アデカスタブ260 以下 E-1)を使用し、下記表1に示す配合比(重量部)で配合し、20分間脱泡を行い、本発明または比較用の硬化性樹脂組成物を得た。
エポキシ樹脂として合成例2で得られたオルガノポリシロキサン化合物(A-2)、硬化剤として、合成例4で得られた硬化剤組成物(T-2)(オルガノポリシロキサン(A)と硬化剤組成物(B)の比率は官能基当量で1:0.8)、有機金属錯体として亜鉛塩(亜鉛錯体)(ホープ製薬製 18%オクトープZn 以下、C-2)、光安定剤としてビス(1-ウンデカンオキシ-2,2,6,6-テトラメチルピペリジン-4-イル)カーボネート(ADEKA製 アデカスタブLA-81 以下 D-1)、ビス(2,2,6,6-テトラメチルー4-ピペリジル)セバケート(チバジャパン製 TINUVIN770DF 以下、D-2と称す。)、ビス(1-オクチルオキシ-2,2,6,6-テトラメチル-4-ピペリジル)(チバジャパン製 TINUVIN123 以下、D-3)を使用し、下記表2に示す配合比(重量部)で配合し、20分間脱泡を行い、本発明または比較用の硬化性樹脂組成物を得た。
得られた硬化性樹脂組成物を試験片用金型に静かに注型し、その注型物を、120℃×1時間の予備硬化の後150℃×3時間の条件で硬化させ試験用の硬化物を得た。得られた硬化物について、以下に記載する条件で熱耐久性透過率試験を実施し、評価を行った(結果を下記表1および表2に示す。)。
測定条件試験条件:180℃オーブン中、72hr放置
試験片サイズ:厚さ0.8mm
評価条件:分光光度計により、400nmの透過率を測定。その変化率を算出。
得られた硬化性樹脂組成物を用い、シリンジに充填し精密吐出装置を用いて、中心発光波465nmのチップを搭載した外径5mm角表面実装型LEDパッケージに注型した。その注型物を加熱炉に投入して、120℃、1時間、さらに150℃、3時間の硬化処理をしてLEDパッケージを作製した。点灯試験は、規定電流である30mAの倍の60mAでの点灯試験を行った(加速試験)。
測定は、1000時間点灯前後の照度保持率を、積分球を使用して測定し、3サンプルの平均値を記録した。詳細な条件は下記に示した(結果を下記表3に示す。)。
点灯詳細条件発光波長:465nm
駆動方式:定電流方式、60mA(発光素子規定電流は30mA)
駆動環境:85℃、85%
エポキシ樹脂として合成例1、2で得られたオルガノポリシロキサン化合物(A-1)、(A-2)、硬化剤として、(T-1)、(T-2)、有機金属錯体として亜鉛塩(亜鉛錯体)(C-1)、(C-2)、4級ホスホニュウム塩(日本化学工業製 ヒシコーリンPX4MP 以下C-3と称す。)、光安定剤として(D-1)、酸化防止剤として(E-1)を使用し、下記表4に示す配合比(重量部)で配合し、20分間脱泡を行い、本発明または比較用の硬化性樹脂組成物を得た。
得られた硬化性樹脂組成物を用い、シリンジに充填し精密吐出装置を用いて、中心発光波465nmのチップを搭載した外径5mm角表面実装型LEDパッケージに注型した。その注型物を加熱炉に投入して、120℃、1時間、さらに150℃、3時間の硬化処理をしてLEDパッケージを作成した。下記条件でLEDパッケージを腐食性ガス中に放置し、封止内部の銀メッキされたリードフレーム部の色の変化を観察した(結果を下記表4に示す。)。
測定条件腐食ガス:硫化アンモニウム20%水溶液(硫黄成分が銀と反応した場合に黒く変色する)
接触方法:広口ガラス瓶の中に、硫化アンモニウム水溶液の容器と前記LEDパッケージを混在させ、広口ガラス瓶の蓋をして密閉状況下、揮発した硫化アンモニウムガスとLEDパッケージを接触させた。
腐食の判定:LEDパッケージ内部のリードフレームが黒く変色(黒化という)した時間を観察し、その変色時間が長い物ほど、耐腐食ガス性にすぐれていると判断した。
観察は10時間後で取り出して確認をし、評価は変色無しの物を○、黒化した物を×と記した。
エポキシ樹脂として合成例1、2で得られたオルガノポリシロキサン化合物(A-1)、(A-2)、硬化剤として、(T-1)、(T-2)、有機金属錯体として亜鉛塩(亜鉛錯体)(C-1)、(C-2)、光安定剤として(D-1)、酸化防止剤として(E-1)を使用し、下記表5に示す配合比(重量部)で配合し、20分間脱泡を行い、本発明または比較用の硬化性樹脂組成物を得た。
得られた硬化性樹脂組成物を用い、試験片用金型に静かに注型し、その注型物を、120℃×1時間の予備硬化の後150℃×3時間の条件で硬化させ試験用の硬化物を得た。得られた硬化物について、以下に記載する条件で光耐久性透過率試験を実施し、評価を行った(結果を下記表5に示す。)。
測定条件試験機: スーパーUVテスター(岩崎電気株式会社)
試験条件:60mW/cm2・nm、200hr
試験片サイズ:厚さ0.8mm
評価条件:分光光度計により、400nmの透過率を測定。その変化率を算出。
なお、本出願は、2010年6月11日付で出願された日本特許出願(特願2010-133745)に基づいており、その全体が引用により援用される。また、ここに引用されるすべての参照は全体として取り込まれる。
Claims (8)
- オルガノポリシロキサン(A)と多価カルボン酸(B)、有機金属塩および/または有機金属錯体(C)、光安定剤(D)を含有する硬化性樹脂組成物、ただし、オルガノポリシロキサン(A)と多価カルボン酸(B)、光安定剤(D)は以下の条件を満たす。
オルガノポリシロキサン(A):少なくとも、その分子中にグリシジル基および/またはエポキシシクロヘキシル基を有するオルガノポリシロキサン
多価カルボン酸(B):少なくとも2つのカルボキシル基を有し、脂肪族炭化水素基を主骨格とする
光安定剤(D):構造式(1)で示される化合物
(ただし、X1,X2は水素原子、炭素数1~50のアルキル基、アラルキル基、アリール基、炭素数1~20のアルキル基を有するアリール基、アルコキシ基または構造式(2)であり、X1,X2の少なくとも一方は構造式(2)である。
(式(2)中、*印で構造式(2)は構造式(1)の酸素原子と結合する。また、Yは水素原子、炭素数1~50のアルキル基、アリール基、アルコキシ基を表す。)) - 構造式(2)のYが炭素数1~20のアルコキシ基である構造式(1)の化合物を含む請求項1に記載の硬化性樹脂組成物。
- 有機金属塩および/または有機金属錯体(C)が亜鉛塩および/または亜鉛錯体である請求項1または請求項2のいずれか一項に記載の硬化性樹脂組成物。
- 構造式(1)のX1、X2がともに構造式(2)であり、かつ、構造式(2)のYが -OC11H23 である請求項1~請求項3のいずれか一項に記載の硬化性樹脂組成物。
- 酸無水物を含有する請求項1~請求項4のいずれか一項に記載の硬化性樹脂組成物。
- 多価カルボン酸(B)が炭素数5以上の2~6官能の多価アルコールと飽和脂肪族環状酸無水物との反応により得られた化合物である請求項1~請求項5のいずれか一項に記載の硬化性樹脂組成物。
- 酸化防止剤を含有する請求項1~請求項6のいずれか一項に記載の硬化性樹脂組成物。
- 請求項1~請求項7のいずれか一項に記載の硬化性樹脂組成物を硬化してなる硬化物。
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KR1020127031434A KR101699773B1 (ko) | 2010-06-11 | 2011-06-10 | 경화성 수지 조성물 및 그 경화물 |
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JP2015510023A (ja) * | 2012-03-16 | 2015-04-02 | ビーエーエスエフ ソシエタス・ヨーロピアBasf Se | 難燃剤としてのnor−hals化合物 |
JP2018188626A (ja) * | 2017-05-11 | 2018-11-29 | 信越化学工業株式会社 | シリコーン変性ポリイミド樹脂組成物 |
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JP5472924B2 (ja) * | 2010-10-21 | 2014-04-16 | 日本化薬株式会社 | 硬化性樹脂組成物およびその硬化物 |
JP6006725B2 (ja) * | 2011-09-09 | 2016-10-12 | 日本化薬株式会社 | 光半導体素子封止用硬化性樹脂組成物およびその硬化物 |
JP6064606B2 (ja) | 2012-01-31 | 2017-01-25 | 日亜化学工業株式会社 | 発光装置 |
DE102013201363A1 (de) | 2012-01-31 | 2013-08-01 | Nichia Corp. | Lichtemittierendes Bauelement |
JP6143359B2 (ja) * | 2013-11-19 | 2017-06-07 | 日本化薬株式会社 | シリコーン変性エポキシ樹脂およびその組成物 |
KR102616534B1 (ko) * | 2015-06-17 | 2023-12-26 | 주식회사 다이셀 | 경화성 조성물, 접착 시트, 경화물, 적층물, 접착 시트의 제조 방법, 및 장치 |
CN116162325A (zh) | 2017-12-27 | 2023-05-26 | 3M创新有限公司 | 适用于电子器件外罩的固化环氧树脂组合物、制品和方法 |
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JP5626856B2 (ja) | 2014-11-19 |
CN102939313A (zh) | 2013-02-20 |
KR20130112694A (ko) | 2013-10-14 |
TWI494376B (zh) | 2015-08-01 |
CN102939313B (zh) | 2016-03-16 |
TW201207043A (en) | 2012-02-16 |
KR101699773B1 (ko) | 2017-01-25 |
SG186252A1 (en) | 2013-01-30 |
JP2011256326A (ja) | 2011-12-22 |
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