WO2018047868A1 - 接着剤組成物、封止シート、及び封止体 - Google Patents
接着剤組成物、封止シート、及び封止体 Download PDFInfo
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- WO2018047868A1 WO2018047868A1 PCT/JP2017/032138 JP2017032138W WO2018047868A1 WO 2018047868 A1 WO2018047868 A1 WO 2018047868A1 JP 2017032138 W JP2017032138 W JP 2017032138W WO 2018047868 A1 WO2018047868 A1 WO 2018047868A1
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
- C09J123/26—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers modified by chemical after-treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/16—Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
- C09J11/02—Non-macromolecular additives
- C09J11/06—Non-macromolecular additives organic
-
- 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
- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
- C09J11/08—Macromolecular additives
-
- 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
- C09J163/00—Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
-
- 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
- C09J7/00—Adhesives in the form of films or foils
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1339—Gaskets; Spacers; Sealing of cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
- H01L21/50—Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
- H01L21/56—Encapsulations, e.g. encapsulation layers, coatings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/02—Details
- H05B33/04—Sealing arrangements, e.g. against humidity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
-
- 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
- C09J2301/00—Additional features of adhesives in the form of films or foils
- C09J2301/30—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier
- C09J2301/312—Additional features of adhesives in the form of films or foils characterized by the chemical, physicochemical or physical properties of the adhesive or the carrier parameters being the characterizing feature
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
- H10K59/871—Self-supporting sealing arrangements
- H10K59/8722—Peripheral sealing arrangements, e.g. adhesives, sealants
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the present invention relates to an adhesive composition, a sealing sheet having an adhesive layer formed from the adhesive composition, and a sealing body in which an object to be sealed is sealed with the sealing sheet.
- organic EL elements have attracted attention as light-emitting elements that can emit light with high luminance by low-voltage direct current drive.
- the organic EL element has a problem that light emission characteristics such as light emission luminance, light emission efficiency, and light emission uniformity are likely to deteriorate with time.
- the organic EL element was sealed using a sealing material.
- oxygen and moisture have been prevented from entering.
- Patent Document 1 describes an organic EL device sealing composition containing a specific cationic curable compound, a photocationic polymerization initiator, and an azole compound.
- Patent Document 1 describes that a cured product having low outgassing properties and moisture resistance can be formed by using a sealing composition using an azole compound used as a curing retarder.
- the gas barrier layer and the resin layer have a low affinity with the resin.
- the adhesive composition is also required to have characteristics as a material for forming a layer having excellent interlayer adhesion with the gas barrier layer.
- the present invention has been made in view of the above circumstances, and has an excellent low outgassing property and unevenness followability, and can be a sealing material having a high effect of suppressing deterioration of an object to be sealed.
- Adhesive composition suitable as a material for forming an adhesive layer having excellent adhesion, a sealing sheet having an adhesive layer formed from the adhesive composition, and an object to be sealed are sealed with the sealing sheet It aims at providing the sealing body stopped.
- the present inventors have found that an adhesive composition containing a modified polyolefin resin and a polyfunctional epoxy compound can solve the above-mentioned problems, and have completed the present invention.
- the present invention relates to the following [1] to [16].
- An adhesive composition in which a sheet-like material formed from the adhesive composition satisfies the following requirements (I) and (II).
- the adhesive composition of the present invention has excellent low outgassing and unevenness followability, it can be a sealing material having a high effect of suppressing deterioration of the object to be sealed. Moreover, the adhesive bond layer formed from the said adhesive composition is excellent also in the interlayer adhesiveness with a gas barrier layer.
- the lower limit value and the upper limit value described in a stepwise manner can be independently combined for a preferable numerical range (for example, a range of content and the like).
- a preferable numerical range for example, a range of content and the like.
- a preferable numerical range for example, a range of content and the like.
- preferably 10 to 90, more preferably 30 to 60 “preferable lower limit (10)” and “more preferable upper limit (60)” are combined to obtain “10 to 60”. You can also.
- the adhesive composition of the present invention contains a modified polyolefin resin (A) and a polyfunctional epoxy compound (B), and a sheet-like material formed from the adhesive composition has the following requirements (I) and (II ).
- Requirement (I) The storage elastic modulus G ′ at 80 ° C. of the sheet-like material is 0.3 MPa or less.
- Requirement (II) The amount of outgas generated per cm 3 of the sheet-like material when the sheet-like material is allowed to stand in an environment of 120 ° C. for 20 minutes is 20 mg / cm 3 or less.
- the adhesive composition of the present invention becomes a sealing material with excellent unevenness followability. obtain. Further, as defined in the requirement (II), since the amount of outgas that can be generated per 1 cm 3 of the sheet-like material is 20 mg / cm 3 or less, the adhesive composition of the present invention has a low outgassing property. It can be said that it is a material. That is, since the adhesive composition of the present invention is prepared so as to satisfy the above requirements (I) and (II), it has excellent low outgassing property and unevenness followability, and deterioration of the sealed object. It can become a sealing material with a high inhibitory effect.
- the storage elastic modulus G ′ at 80 ° C. of the sheet-like material specified in the requirement (I) is preferably 0 from the viewpoint of providing a sealing material that is more excellent in uneven followability. .2 MPa or less, more preferably 0.1 MPa or less, further preferably 0.09 MPa or less, and from the viewpoint of handleability, it is usually 0.001 MPa or more, preferably 0.005 MPa or more, more preferably 0.01 MPa or more. It is.
- regulated by requirement (I) means the value measured by the method as described in an Example.
- regulated by requirement (II) means the value measured by the method as described in an Example.
- the sheet-like material formed from the said adhesive composition satisfy
- the haze of the said sheet-like material is 2.0% or less.
- the adhesive composition is suitably used as a sealing material for sealing an optical element such as an organic EL element. Can be done.
- the haze of the sheet-like material specified by the requirement (III) is preferably 2.0% or less, more preferably 1.5% or less, still more preferably. 1.0% or less.
- regulated by requirement (III) means the value measured by the method as described in an Example.
- the adhesive composition of the present invention is prepared so as to satisfy the above requirements (I) and (II) by containing the modified polyolefin resin (A) and the polyfunctional epoxy compound (B) in combination. . More specific methods for preparing an adhesive composition satisfying the above requirements (I) to (III) are as described for each component described in detail below.
- the adhesive composition of the present invention may contain components other than components (A) and (B) as long as the above requirements (I) and (II) are satisfied and the effects of the present invention are not impaired.
- the adhesive composition of the present invention further contains one or more selected from a tackifier (C), an imidazole-based curing catalyst (D), and a silane coupling agent (E). It is more preferable to further contain components (C), (D), and (E).
- the total content of components (A) and (B) is preferably 30% by mass or more with respect to the total amount (100% by mass) of active ingredients of the adhesive composition. More preferably 50% by mass or more, further preferably 60% by mass or more, still more preferably 65% by mass or more, particularly preferably 70% by mass or more, and usually 100% by mass or less, preferably 99.9% by mass. It is as follows.
- the total content of the components (A), (B), (C), (D) and (E) is 100% by mass of the active ingredients in the adhesive composition.
- the active ingredient of an adhesive composition refers to the component except the dilution solvent which does not participate in the physical property contained in an adhesive composition.
- the adhesive composition of the present invention contains a modified polyolefin resin (A).
- the adhesive composition of the present invention contains the modified polyolefin resin (A), so that the composition has excellent adhesive strength, and the formability of a sheet-like product (adhesive layer) having a relatively thin film thickness. Can be good.
- a modified polyolefin resin (A) may be used independently and may use 2 or more types together.
- the modified polyolefin resin is a polyolefin resin having a functional group obtained by subjecting a polyolefin resin as a precursor to a modification treatment using a modifier having a functional group.
- the polyolefin resin refers to a polymer having a repeating unit derived from an olefin monomer.
- the polyolefin resin may be a polymer composed only of repeating units derived from olefinic monomers, or together with repeating units derived from olefinic monomers, an olefinic unit. It may be a copolymer having a repeating unit derived from a monomer other than a monomer.
- the above olefinic monomer is preferably an ⁇ -olefin having 2 to 8 carbon atoms, more preferably ethylene, propylene, 1-butene, isobutylene, or 1-hexene, and still more preferably ethylene or propylene.
- Examples of the monomer other than the olefin monomer include vinyl acetate, (meth) acrylic acid ester, and styrene.
- polystyrene resin examples include very low density polyethylene (VLDPE), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), linear low density polyethylene, polypropylene (PP), ethylene- Examples thereof include a propylene copolymer, an olefin elastomer (TPO), an ethylene-vinyl acetate copolymer (EVA), an ethylene- (meth) acrylic acid copolymer, and an ethylene- (meth) acrylic acid ester copolymer.
- VLDPE very low density polyethylene
- LDPE low density polyethylene
- MDPE medium density polyethylene
- HDPE high density polyethylene
- PP polypropylene
- ethylene- Examples thereof include a propylene copolymer, an olefin elastomer (TPO), an ethylene-vinyl acetate copolymer (EVA), an ethylene- (meth) acrylic acid copolymer, and an ethylene- (me
- the modifier used for the modification treatment of the polyolefin resin may be a compound having a functional group in the molecule, that is, a group that can contribute to a crosslinking reaction described later.
- functional groups carboxyl groups, groups derived from carboxylic anhydrides, carboxylic ester groups, hydroxyl groups, epoxy groups, amide groups, ammonium groups, nitrile groups, amino groups, imide groups, isocyanate groups, acetyl groups, thiol groups Ether group, thioether group, sulfone group, phosphone group, nitro group, urethane group, halogen atom and the like.
- a carboxyl group, a group derived from a carboxylic acid anhydride, a carboxylic acid ester group, a hydroxyl group, an ammonium group, an amino group, an imide group, or an isocyanate group are preferable, and a group derived from a carboxylic acid anhydride, or an alkoxysilyl group A group is more preferable, and a group derived from a carboxylic acid anhydride is still more preferable.
- the modifier used may be a compound having two or more functional groups in the molecule.
- the modified polyolefin resin (A) is preferably an acid-modified polyolefin resin or a silane-modified polyolefin resin from the viewpoint of an adhesive composition that satisfies the above requirements (I) and (II). More preferred.
- the acid-modified polyolefin resin refers to a polyolefin resin obtained by graft modification with an acid having a functional group as a modifier.
- examples thereof include those obtained by reacting an unsaturated carboxylic acid and / or an unsaturated carboxylic acid anhydride with a polyolefin resin to introduce a carboxyl group and / or a group derived from the carboxylic acid anhydride (graft modification).
- Examples of the unsaturated carboxylic acid and unsaturated carboxylic acid anhydride to be reacted with the polyolefin resin include maleic acid, fumaric acid, itaconic acid, citraconic acid, glutaconic acid, tetrahydrophthalic acid, aconitic acid, maleic anhydride, and itaconic anhydride.
- Examples thereof include acid, glutaconic anhydride, citraconic anhydride, aconitic anhydride, norbornene dicarboxylic acid anhydride, and tetrahydrophthalic acid anhydride. These may be used alone or in combination of two or more.
- maleic anhydride is preferable from the viewpoint of improving the adhesive strength and achieving an adhesive composition that satisfies the above requirements (I) and (II).
- the amount is preferably 0.1 to 5 parts by mass, more preferably 0.2 to 3 parts by mass, and still more preferably 0.2 to 1.0 parts by mass with respect to 100 parts by mass of the polyolefin resin before modification.
- a commercially available product can be used as the acid-modified polyolefin resin.
- examples of commercially available acid-modified polyolefin resins include Admer (registered trademark) (manufactured by Mitsui Chemicals), Unistor (registered trademark) (manufactured by Mitsui Chemicals), BondyRam (manufactured by Polyram), and orevac (registered).
- Trademark (manufactured by ARKEMA), Modic (registered trademark) (manufactured by Mitsubishi Chemical Corporation), and the like.
- the silane-modified polyolefin resin refers to a polyolefin resin that is graft-modified with an unsaturated silane compound that is a modifier. That is, the silane-modified polyolefin resin has a structure in which an unsaturated silane compound as a side chain is graft copolymerized with a polyolefin resin as a main chain.
- the unsaturated silane compound to be reacted with the polyolefin resin is preferably a vinyl silane compound, for example, vinyl trimethoxy silane, vinyl triethoxy silane, vinyl tripropoxy silane, vinyl triisopropoxy silane, vinyl tributoxy silane, vinyl tripentyloxy silane.
- These unsaturated silane compounds may be used alone or in combination of two or more.
- the blending amount of the unsaturated silane compound to be reacted with the polyolefin resin is 100 parts by mass of the polyolefin resin before modification from the viewpoint of improving the adhesive strength and satisfying the above requirements (I) and (II). Is preferably 0.1 to 10 parts by mass, more preferably 0.3 to 7 parts by mass, and still more preferably 0.5 to 5 parts by mass.
- silane-modified polyolefin resin examples include a silane-modified polyethylene resin and a silane-modified ethylene-vinyl acetate copolymer, such as a silane-modified low-density polyethylene, a silane-modified ultra-low-density polyethylene, and a silane-modified linear chain.
- a silane-modified polyethylene resin such as a low-density polyethylene is preferred.
- silane-modified polyolefin resin a commercially available product can be used as the silane-modified polyolefin resin.
- Commercially available silane-modified polyolefin resins include, for example, Rinklon (registered trademark) (manufactured by Mitsubishi Chemical Corporation), etc., but low-density polyethylene-based linklon and linear low-density polyethylene-based linklon. Ultra low density polyethylene based rinklon and ethylene-vinyl acetate copolymer based rinklon are preferred.
- the adhesive strength is further improved and the adhesive composition satisfying the above requirements (I) and (II), and the adhesive composition
- the adhesive composition From the viewpoint of improving the shape maintaining property when the product is formed into a sheet, it is preferably 10,000 to 2,000,000, more preferably 20,000 to 1,500,000, and still more preferably 25,000 to 250,000, and more preferably 30,000 to 150,000. Since the weight average molecular weight of the modified polyolefin resin (A) is in the above range, even if the content of the modified polyolefin resin (A) in the adhesive composition is large, a sheet from the adhesive composition is used. When formed into a shape, the shape maintainability of the shape becomes good.
- the weight average molecular weight (Mw) is a standard polystyrene conversion value measured by gel permeation chromatography (GPC) method using tetrahydrofuran as a solvent. It is the value measured based on the described method. Same in the following.
- the modified polyolefin resin (A) is preferably a solid at room temperature (25 ° C.) from the viewpoint of improving the shape maintaining property when the adhesive composition is formed into a sheet.
- the content of the component (A) is preferably 15 to 70% by mass, more preferably 23 to 30%, based on the total amount (100% by mass) of the active ingredients of the adhesive composition. 60% by mass, more preferably 30 to 50% by mass.
- the adhesive composition of the present invention contains a polyfunctional epoxy compound (B).
- the adhesive composition of the present invention can be a sealing material having excellent water vapor barrier properties.
- a polyfunctional epoxy compound (B) may be used independently and may use 2 or more types together.
- the polyfunctional epoxy compound refers to a compound having at least two epoxy groups in the molecule.
- fills the said requirements (I) and (II) is preferable.
- Bifunctional epoxy compounds include bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, bisphenol S diglycidyl ether, brominated bisphenol A diglycidyl ether, brominated bisphenol F diglycidyl ether, brominated bisphenol S diglycidyl ether, novolak Type epoxy resin (for example, phenol / novolak type epoxy resin, cresol / novolac type epoxy resin, brominated phenol / novolac type epoxy resin); hydrogenated bisphenol A diglycidyl ether, hydrogenated bisphenol F diglycidyl ether , Cycloaliphatic epoxy compounds such as hydrogenated bisphenol S diglycidyl ether; pentaerythritol polyglycidyl ether, 1,6-hexane All diglycidyl ether, hexahydrophthalic acid diglycidyl ester, neopentyl glycol diglycidyl ether, trimethylolpropane polyglycid
- the polyfunctional epoxy compound (B) is at least one selected from polyfunctional alicyclic epoxy compounds and polyfunctional aliphatic epoxy compounds. It is preferable.
- the sealing material formed from the adhesive composition containing an aromatic epoxy compound tends to have high haze. Therefore, from the viewpoint of obtaining an adhesive composition that satisfies the requirement (III), the content of the aromatic epoxy compound is preferably as small as possible. From the above viewpoint, the content of the aromatic epoxy compound is preferably 0 to 50% by mass, more preferably 0 to 20% by mass, and still more preferably 0 to 0% by mass with respect to the total amount (100% by mass) of the component (B). The amount is 10% by mass, and more preferably 0 to 2% by mass.
- the adhesive composition of the present invention preferably contains a polyfunctional epoxy compound (B1) that is liquid at 25 ° C. as the component (B).
- the component (B1) has an effect of lowering the storage elastic modulus of the adhesive composition when the adhesive composition reaches a high temperature (hereinafter sometimes referred to as “storage elastic modulus lowering effect”). For this reason, the adhesive composition which is excellent in uneven
- the weight average molecular weight (Mw) of the polyfunctional epoxy compound (B1) that is liquid at 25 ° C. is preferably 1,000 or more, more preferably 1, from the viewpoint of an adhesive composition that satisfies the requirement (II). 200 or more, more preferably 1,500 or more, still more preferably 1,800 or more, particularly preferably 2,100 or more. From the viewpoint of forming an adhesive composition that satisfies the requirement (I), the weight average molecular weight (Mw) of the polyfunctional epoxy compound (B1) that is liquid at 25 ° C. is preferably 4,000 or less, more preferably 3 700 or less, more preferably 3,400 or less.
- the epoxy equivalent of the polyfunctional epoxy compound (B1) that is liquid at 25 ° C. is preferably 100 to 500 g / eq, more preferably 120 to 400 g / eq, and still more preferably 150 to 300 g / eq.
- the adhesive composition of the present invention preferably contains a polyfunctional epoxy compound (B2) that is solid at 25 ° C. as the component (B). Unlike the polyfunctional epoxy compound of the component (B1), the polyfunctional epoxy compound of the component (B2) is considered to have little storage elastic modulus lowering effect. On the other hand, when the adhesive composition contains the component (B2), the performance of the adhesive layer maintaining the sheet shape is improved. As a result of such a tendency, when the component (B2) is used in combination with the component (B1), the storage elastic modulus lowering effect of the component (B1) can be further enhanced. By the presence of the component (B2), the content of the component (B) in the adhesive composition can be increased while maintaining the performance of maintaining the sheet shape of the adhesive layer.
- the ratio of the continuous phase region of the component (B) increases.
- the adhesive composition of the present invention contains both the component (B1) and the component (B2).
- the weight average molecular weight (Mw) of the polyfunctional epoxy compound (B2) that is solid at 25 ° C. is preferably 3,800 or more, more preferably 4,000 or more.
- the sheet shape of the adhesive layer is more easily maintained.
- the weight average molecular weight (Mw) of the polyfunctional epoxy compound (B2) which is solid at 25 ° C. is preferably 8,000 or less, more preferably 7,000 or less.
- the epoxy equivalent of the polyfunctional epoxy compound (B2) that is solid at 25 ° C. is preferably 600 to 6,000 g / eq, more preferably 700 to 5,500 g / eq.
- the content of the component (B) is preferably from 100 parts by weight of the component (A) from the viewpoint of an adhesive composition satisfying the requirements (I) and (II).
- the amount is 25 to 200 parts by mass, more preferably 30 to 180 parts by mass, still more preferably 50 to 150 parts by mass, and still more preferably 65 to 120 parts by mass.
- the amount of the component (B2) relative to the component (B1) increases, a certain shape tends to be maintained when the adhesive composition is formed into a sheet.
- the adhesive composition of the present invention preferably further contains a tackifier (C) from the viewpoint of improving the shape maintaining property of the formed sealing material.
- tackifier (C) examples include rosin resins such as polymerized rosin, polymerized rosin ester, and rosin derivatives; terpene resins such as polyterpene resins, aromatic modified terpene resins and hydrides thereof, and terpene phenol resins; Indene resins; aliphatic petroleum resins, aromatic petroleum resins and their hydrides, petroleum resins such as aliphatic / aromatic copolymer petroleum resins; styrene or substituted styrene polymers; ⁇ -methylstyrene monopolymer resins Copolymers of ⁇ -methylstyrene and styrene, copolymers of styrene monomers and aliphatic monomers, copolymers of styrene monomers, ⁇ -methylstyrene and aliphatic monomers, styrene monomers And a styrene resin such as a copo
- tackifiers (C) may be used alone or in combination of two or more.
- a styrene resin is preferable, and a copolymer of a styrene monomer and an aliphatic monomer is more preferable.
- the softening point of the tackifier (C) is preferably from the viewpoint of further improving the shape maintaining property of the formed sealing material and making the adhesive composition capable of expressing excellent adhesiveness even in a high temperature environment.
- the temperature is 80 ° C or higher, more preferably 85 to 170 ° C, still more preferably 90 to 150 ° C.
- the softening point means a value measured according to JIS K 5902. When using 2 or more types of several tackifier, it is preferable that the weighted average of the softening point of these several tackifiers belongs to the said range.
- the content of the component (C) is 100 parts by mass of the component (A) from the viewpoint of making the adhesive composition having better shape maintainability of the formed sealing material.
- it is preferably 1 to 200 parts by mass, more preferably 10 to 150 parts by mass, still more preferably 15 to 100 parts by mass, and still more preferably 20 to 80 parts by mass.
- the adhesive composition of the present invention preferably further contains an imidazole-based curing catalyst (D) from the viewpoint of an adhesive composition that can exhibit excellent adhesiveness even in a high-temperature environment.
- imidazole curing catalyst (D) examples include 2-methylimidazole, 2-phenylimidazole, 2-undecylimidazole, 2-heptadecylimidazole, 2-ethyl-4-methylimidazole, 2-phenyl-4-methylimidazole, Examples thereof include 2-phenyl-4-methyl-5-hydroxymethylimidazole and 2-phenyl-4,5-dihydroxymethylimidazole.
- These imidazole-based curing catalysts (D) may be used alone or in combination of two or more. Of these, 2-ethyl-4-methylimidazole is preferred as component (D).
- the content of the component (D) is based on 100 parts by mass of the component (A) component from the viewpoint of an adhesive composition that can exhibit excellent adhesiveness even in a high temperature environment.
- the amount is preferably 0.1 to 10 parts by mass, more preferably 0.2 to 5 parts by mass, and still more preferably 0.3 to 2.5 parts by mass.
- the adhesive composition of the present invention further includes a silane coupling agent (E) from the viewpoint of an adhesive composition capable of forming a sealing body having excellent adhesive strength in both normal temperature and high temperature environments. It is preferable to contain.
- the silane coupling agent (E) is preferably an organosilicon compound having at least one alkoxysilyl group in the molecule.
- Specific examples of the silane coupling agent (E) include polymerizable unsaturated group-containing silicon compounds such as vinyltrimethoxysilane, vinyltriethoxysilane, and methacryloxypropyltrimethoxysilane; 3-glycidoxypropyltrimethoxy Silicon compounds having an epoxy structure such as silane, glycidoxyoctyltrimethoxysilane, 2- (3,4-epoxycyclohexyl) ethyltrimethoxysilane; 3-aminopropyltrimethoxysilane, N- (2-aminoethyl)- Amino group-containing silicon compounds such as 3-aminopropyltrimethoxysilane, N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane; 3-chlor
- the content of the component (E) is from the viewpoint of an adhesive composition that can form a sealed body having excellent adhesive strength in both normal temperature and high temperature environments.
- the amount is preferably 0.01 to 10 parts by mass, more preferably 0.02 to 5 parts by mass, and still more preferably 0.05 to 2 parts by mass with respect to 100 parts by mass of the component (A).
- the adhesive composition of the present invention may contain other additives other than the above-mentioned components (A) to (E) as long as the effects of the present invention are not impaired.
- Other additives are appropriately selected depending on the application, but examples include UV absorbers, antistatic agents, light stabilizers, antioxidants, resin stabilizers, fillers, pigments, extenders, softeners, etc. These additives may be mentioned. These additives may be used alone or in combination of two or more.
- the content of the filler and the pigment is preferably as small as possible.
- the total content of the filler and the pigment is preferably 0 to 10% by mass, more preferably 0 to 5% by mass with respect to the total amount (100% by mass) of the active ingredients of the adhesive composition. More preferably, it is 0 to 1% by mass, and still more preferably 0 to 0.001% by mass.
- the adhesive composition of this invention may contain a dilution solvent from a viewpoint which makes moldability favorable.
- the dilution solvent can be appropriately selected from organic solvents. Specifically, aromatic hydrocarbon solvents such as benzene and toluene; ester solvents such as ethyl acetate and butyl acetate; acetone, methyl ethyl ketone, Ketone solvents such as methyl isobutyl ketone; aliphatic hydrocarbon solvents such as n-pentane, n-hexane and n-heptane; alicyclic hydrocarbon solvents such as cyclopentane, cyclohexane and methylcyclohexane; . These solvents may be used alone or in combination of two or more. The content of the solvent can be appropriately set in consideration of applicability and the like.
- the sealing sheet of this invention has the adhesive bond layer formed from the above-mentioned adhesive composition.
- the thickness of the adhesive layer is appropriately set depending on the application, but is preferably 2 to 50 ⁇ m, more preferably 5 to 25 ⁇ m, and still more preferably 10 to 20 ⁇ m.
- the haze of the adhesive layer of the sealing sheet of the present invention is preferably 2.0% or less, more preferably 1.5% or less, and still more preferably 1.0% or less.
- the adhesive layer of the encapsulating sheet of the present invention is the same as the sheet-like material specified in the above requirements (I) to (II). Therefore, the preferable ranges of the storage elastic modulus G ′ and the outgas amount at 80 ° C. for the adhesive layer of the sealing sheet of the present invention are the same as the ranges specified in the above requirements (I) and (II), respectively. is there.
- the adhesive layer of the encapsulating sheet of the present invention preferably has thermosetting properties. Such an adhesive layer is extremely excellent in adhesive strength after curing.
- the conditions for thermosetting the adhesive layer are not particularly limited, but the heating temperature is usually 80 to 200 ° C. (preferably 90 to 150 ° C.), and the heating time is usually 30 minutes to 12 hours (preferably 1). ⁇ 6 hours).
- sealing sheet of the present invention include the following sealing sheet ( ⁇ ) and sealing sheet ( ⁇ ).
- -Sealing sheet ((alpha)) The sealing sheet which has the structure which pinched
- -Sealing sheet ((beta)) The sealing sheet which has a gas-barrier film which has a base material layer and a gas barrier layer, and the adhesive bond layer formed from the adhesive composition of this invention.
- a release film may be further laminated on the adhesive layer.
- these sealing sheets represent the state before use, and when using the sealing sheet of this invention, a peeling film is peeled and removed normally.
- the release film constituting the sealing sheet ( ⁇ ) functions as a support in the manufacturing process of the sealing sheet ( ⁇ ) and protects the adhesive layer until the sealing sheet ( ⁇ ) is used. Functions as a sheet.
- a conventionally well-known thing can be utilized as a peeling film.
- the release film substrate include paper substrates such as glassine paper, coated paper, and high-quality paper; laminated paper obtained by laminating a thermoplastic resin such as polyethylene on these paper substrates; polyethylene terephthalate resin, polybutylene terephthalate resin And a plastic film formed from polyethylene naphthalate resin, polypropylene resin, polyethylene resin, and the like.
- the release agent include rubber elastomers such as silicone resins, olefin resins, isoprene resins, and butadiene resins, long chain alkyl resins, alkyd resins, and fluorine resins.
- the two release films of the sealing sheet ( ⁇ ) may be the same or different from each other, but preferably have different release forces.
- sealing sheet ((alpha)) is not specifically limited,
- the adhesive composition of this invention is apply
- a sealing sheet ( ⁇ ) can be obtained by laminating another release film.
- Examples of the method for applying the adhesive composition include spin coating, spray coating, bar coating, knife coating, roll coating, blade coating, die coating, and gravure coating. Further, from the viewpoint of improving applicability, it is preferable to add the above-described dilution solvent to the adhesive composition to form a solution.
- drying conditions for drying the coating film for example, it is usually preferable to perform a drying treatment at 80 to 150 ° C. for 30 seconds to 5 minutes.
- the gas barrier film included in the sealing sheet ( ⁇ ) includes a base material layer and a gas barrier layer.
- the gas barrier film may have a configuration in which a base material layer and a gas barrier layer are directly laminated.
- a primer layer is provided in order to improve adhesion between the base material layer and the gas barrier layer. It is good also as a provided structure.
- the sealing sheet ( ⁇ ) has a structure in which the gas barrier layer and the adhesive layer of the gas barrier film are directly laminated.
- the gas barrier layer is a polymer layer containing a polymer compound and subjected to a modification treatment as described later
- the interlayer adhesion between a general adhesive layer and the gas barrier layer is improved. May be inferior.
- the adhesive layer formed from the adhesive composition of the present invention contains the polyfunctional epoxy resin (B) together with the modified polyolefin resin (A), so that the gas barrier layer which is such a polymer layer can be used. It can be excellent in interlayer adhesion.
- the sealing sheet (beta), temperature 40 ° C., water vapor permeability at an environment of 90% RH (relative humidity) is preferably not more than 0.1g / m 2 / day, more preferably 0.05 g / m 2 / Day or less, more preferably 0.005 g / m 2 / day or less. If the water vapor transmission rate of the sealing sheet ( ⁇ ) is 0.1 g / m 2 / day or less, the entry of oxygen or moisture into the inside of the element such as the organic EL element formed on the transparent substrate is suppressed. It can suppress effectively that an organic layer deteriorates. In the present specification, the water vapor transmission rate can be measured using a general gas transmission rate measuring device.
- the gas permeability measuring device examples include a product name “PERMATRAN” manufactured by mocon.
- the water vapor transmission rate of the sealing sheet ( ⁇ ) is a value measured in a state where the sealing sheet ( ⁇ ) is used, that is, for example, the sealing sheet ( ⁇ ) has a release film. When it is provided, it is a value measured by removing the release film.
- a resin film containing a resin component is preferable.
- the resin component includes polyimide, polyamide, polyamideimide, polyphenylene ether, polyether ketone, polyether ether ketone, polyolefin, polyester, polycarbonate, polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, acrylic resin, cycloolefin Examples thereof include a polymer, an aromatic polymer, and a polyurethane polymer. These resin components may be used independently and may use 2 or more types together.
- the thickness of the base material layer included in the gas barrier film is not particularly limited, but is preferably 0.5 to 500 ⁇ m, more preferably 1 to 200 ⁇ m, and still more preferably 5 to 100 ⁇ m from the viewpoint of ease of handling.
- the gas barrier layer of the gas barrier film includes an inorganic film or a polymer compound and is subjected to a modification treatment from the viewpoint that the thickness of the gas barrier film can be reduced and has an excellent gas barrier property.
- the polymer layer is preferable, and the polymer layer is more preferable. Since the polymer layer containing the polymer compound and subjected to the modification treatment is excellent in flexibility, the gas barrier layer is the polymer layer, so that the gas barrier laminate having excellent bending resistance and can do.
- Examples of the polymer compound contained in the polymer layer include silicon-containing polymer compounds such as polyorganosiloxane and polysilazane compounds, polyimide, polyamide, polyamideimide, polyphenylene ether, polyether ketone, polyether ether ketone, polyolefin, Examples thereof include polyester, polycarbonate, polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, acrylic resin, cycloolefin polymer, and aromatic polymer. These high molecular compounds may be used independently and may use 2 or more types together.
- the polymer compound contained in the polymer layer is preferably a silicon-containing polymer compound, and more preferably a polysilazane compound.
- the number average molecular weight of the polysilazane compound is preferably 100 to 50,000.
- the polysilazane compound is a polymer having a repeating unit containing —Si—N— bond (silazane bond) in the molecule, specifically, a polymer having a repeating unit represented by the following general formula (1) It is preferable that
- n represents the number of repeating units and represents an integer of 1 or more.
- Rx, Ry, and Rz each independently represent a hydrogen atom, an unsubstituted or substituted alkyl group, an unsubstituted or substituted cycloalkyl group, an unsubstituted or substituted alkenyl group, unsubstituted or substituted
- An aryl group or alkylsilyl group having a group is represented.
- Rx, Ry, and Rz a hydrogen atom, an alkyl group having 1 to 6 carbon atoms, or a phenyl group is preferable, and a hydrogen atom is more preferable.
- the polymer compound contained in the gas barrier layer may be an inorganic polysilazane in which Rx, Ry, and Rz in the general formula (1) are all hydrogen atoms, and at least one of Rx, Ry, and Rz is hydrogen.
- Organic polysilazanes which are groups other than atoms may be used.
- a polysilazane compound may be used independently and may use 2 or more types together. Moreover, a polysilazane modified material can also be used as a polysilazane compound, and a commercial item can also be used.
- the polymer layer may further contain other components as long as the effects of the present invention are not impaired.
- other components include curing agents, other polymers, anti-aging agents, light stabilizers, flame retardants, and the like.
- the content of the polymer compound in the polymer layer is preferably 50 to 100 with respect to the total amount (100% by mass) of the components in the polymer layer from the viewpoint of obtaining a gas barrier layer having better gas barrier properties.
- the mass is more preferably 70 to 100% by mass, still more preferably 80 to 100% by mass.
- the thickness of the polymer layer of the gas barrier film is preferably 50 to 300 nm, more preferably 50 to 200 nm.
- a sealing sheet having a sufficient gas barrier property can be obtained even if the thickness of the polymer layer is nano-order.
- a solution for forming a polymer layer containing at least one polymer compound, optionally other components, a solvent, etc. is applied to a spin coater, knife coater, gravure coater, etc.
- a method of forming a coating film by applying using a known apparatus and drying the coating film is exemplified.
- Examples of the polymer layer modification treatment include ion implantation treatment, plasma treatment, radiation irradiation treatment, heat treatment and the like, and treatment for changing the bonding structure of the polymer layer is preferable. These processes can be performed alone or in combination of two or more.
- the ion implantation process is a method of modifying the polymer layer by implanting ions into the polymer layer, as will be described later.
- the plasma treatment is a method for modifying the polymer layer by exposing the polymer layer to plasma.
- plasma treatment can be performed according to the method described in Japanese Patent Application Laid-Open No. 2012-106421.
- the radiation irradiation treatment is a method for modifying the polymer layer by irradiating the polymer layer with radiation.
- the radiation preferably has a short wavelength with a high effect of changing the bonding structure of the polymer layer, and it is preferable to use ultraviolet rays, particularly vacuum ultraviolet rays.
- the vacuum ultraviolet light modification treatment can be performed according to the method described in JP2013-226757A.
- the polymer layer is modified by ion implantation. Treatment is preferred.
- Examples of ions implanted into the polymer layer during the ion implantation process include ions of rare gases such as argon, helium, neon, krypton, and xenon; fluorocarbon, hydrogen, nitrogen, oxygen, carbon dioxide, chlorine, fluorine Ions of alkane gases such as methane and ethane; ions of alkene gases such as ethylene and propylene; ions of alkadiene gases such as pentadiene and butadiene; ions of alkyne gases such as acetylene Ions; ions of aromatic hydrocarbon gases such as benzene and toluene; ions of cycloalkane gases such as cyclopropane; ions of cycloalkene gases such as cyclopentene; metal ions; ions of organosilicon compounds; Is mentioned.
- rare gases such as argon, helium, neon, krypton, and xenon
- fluorocarbon hydrogen, nitrogen, oxygen
- ions may be used alone or in combination of two or more.
- ions of rare gases such as argon, helium, neon, krypton, xenon are preferable from the viewpoint that ions can be more easily implanted and a gas barrier layer having particularly excellent gas barrier properties can be obtained.
- Argon ions are more preferred.
- the method for implanting ions is not particularly limited. For example, there are a method of irradiating ions accelerated by an electric field (ion beam), a method of injecting ions in plasma (ion of plasma generation gas), etc., and a gas barrier layer can be easily obtained.
- a method of implanting ions (hereinafter sometimes referred to as “plasma ion implantation method”) is preferable.
- plasma ion implantation method for example, plasma is generated in an atmosphere containing a plasma generation gas, and a negative high voltage pulse is applied to a layer into which ions are implanted, whereby ions (positive ions) in the plasma are ionized. Can be performed by injecting into the surface portion of the layer to be injected.
- the manufacturing method of a sealing sheet ((beta)) is not specifically limited.
- the sealing sheet ( ⁇ ) can be manufactured by replacing one of the release films with a gas barrier film.
- one of the two release films of the sealing sheet ( ⁇ ) is peeled off, and the exposed adhesive layer and the gas barrier layer of the gas barrier film are pasted.
- the sealing sheet ( ⁇ ) can also be manufactured by wearing. In this case, when the sealing sheet ( ⁇ ) has two release films having different release forces, it is preferable to release the release film having the smaller release force from the viewpoint of handleability.
- the sealing sheet of this invention replaces with the peeling film the base material layer which a sealing sheet ((beta)) has, and the structure which clamps a gas barrier layer and an adhesive bond layer with two peeling films. It is good also as the sealing sheet which has.
- the sealing body of the present invention is formed by sealing an object to be sealed with the sealing sheet of the present invention.
- the sealing body of the present invention includes, for example, a transparent substrate, an element (an object to be sealed) formed on the transparent substrate, and a sealing material for sealing the element.
- the sealing material is an adhesive layer of the sealing sheet of the present invention.
- the transparent substrate is not particularly limited, and various substrate materials can be used. In particular, it is preferable to use a substrate material having a high visible light transmittance. In addition, a material having a high blocking performance for blocking moisture and gas to enter from the outside of the element and having excellent solvent resistance and weather resistance is preferable.
- transparent inorganic materials such as quartz and glass; polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polystyrene, polyethylene, polypropylene, polyphenylene sulfide, polyvinylidene fluoride, acetyl cellulose, brominated phenoxy, aramids, polyimides, Examples thereof include transparent plastics such as polystyrenes, polyarylates, polysulfones, and polyolefins, and the gas barrier film described above.
- the thickness of the transparent substrate is not particularly limited, and can be appropriately selected in consideration of light transmittance and performance for blocking the inside and outside of the element.
- Examples of the object to be sealed include an organic EL element, an organic EL display element, a liquid crystal display element, and a solar cell element. That is, it is preferable that the sealing body of this invention seals an organic EL element, an organic EL display element, a liquid crystal display element, or a solar cell element with the sealing sheet of this invention.
- the manufacturing method of the sealing body of this invention is not specifically limited. For example, after the adhesive layer of the sealing sheet of the present invention is stacked on the object to be sealed, the adhesive layer of the sealing sheet and the object to be sealed are bonded by heating. Subsequently, the sealing body of this invention can be manufactured by hardening this adhesive bond layer.
- the bonding temperature is, for example, 23 to 100 ° C., preferably 40 to 80 ° C. This adhesion treatment may be performed while applying pressure.
- the curing conditions for curing the adhesive layer the conditions described above can be used.
- the weight average molecular weight (Mw) of a modified polyolefin resin and a polyfunctional epoxy compound is a value measured by the following method. ⁇ Weight average molecular weight of modified polyolefin resin (Mw)> The weight average molecular weight (Mw) of the modified polyolefin resin was measured using a gel permeation chromatograph (GPC) apparatus (product name “HLC-8320” manufactured by Tosoh Corporation) under the following conditions. The value converted into the weight average molecular weight was used.
- GPC gel permeation chromatograph
- -Imidazole-based curing catalyst Shikoku Kasei Kogyo Co., Ltd., product name "Curazole 2E4MZ", 2-ethyl-4-methylimidazole.
- Silane coupling agent manufactured by Shin-Etsu Chemical Co., Ltd., product name “KBM-4803”, glycidoxyoctyltrimethoxysilane.
- a coating film is formed by applying the prepared adhesive composition on the release-treated surface of a release film (product name “SP-PET382150” manufactured by Lintec Corporation). And the said coating film was dried at 100 degreeC for 2 minute (s), the 12-micrometer-thick sheet-like object (adhesive layer) was formed, and the laminated body which consists of a peeling film and a sheet-like object (adhesive layer) was obtained.
- [Storage elastic modulus G ′ of sheet-like material] A plurality of sheet-like materials (adhesive layers) from which the release films have been removed from the laminates produced in the examples or comparative examples are overlaid and heated and compressed at 60 ° C. using a heat laminator to obtain a laminate having a thickness of 1 mm. It was. Using this laminate as a test sample, the viscoelasticity measuring device (product name “Physica MCR301” manufactured by Anton Paar Co., Ltd.) was used to measure the laminate before curing in a temperature range of 23 to 150 ° C. under a frequency of 1 Hz. The storage elastic modulus G ′ was measured. Table 1 shows the measured values of the storage elastic modulus G ′ at 80 ° C.
- the boundary part between the pseudo device and the cured adhesive layer was observed in a plan view, and a sheet-like material was determined depending on whether there was a gap between the pseudo device and the adhesive layer as follows.
- the unevenness followability was evaluated. A: Since there is no gap between the pseudo device and the adhesive layer, the unevenness followability is good. F: Since a gap is confirmed between the pseudo device and the adhesive layer, the unevenness followability is inferior.
- tris (8-hydroxy-quinolinate) aluminum (manufactured by Luminescence Technology) is deposited on the formed hole transport layer at a rate of 0.1 to 0.2 nm / min to form a light emitting layer having a thickness of 50 nm. did. Further, on the formed light emitting layer, lithium fluoride (LiF) (manufactured by High Purity Chemical Research Laboratories) was deposited at a rate of 0.1 nm / min to form an electron injection layer having a thickness of 4 nm.
- LiF lithium fluoride
- aluminum (manufactured by Kojundo Chemical Laboratory Co., Ltd.) is vapor-deposited on the formed electron injection layer at a rate of 0.1 nm / min to form a cathode having a thickness of 100 nm to obtain an organic EL element. It was.
- the degree of vacuum at the time of vapor deposition was 1 ⁇ 10 ⁇ 4 Pa or less.
- the sheet-like material (adhesive layer) formed from the adhesive compositions of Examples 1 to 3 produced a small amount of outgas, had excellent unevenness followability, and had good evaluation of sealing properties. Therefore, it can be said that the sealing sheet which has the adhesive bond layer formed from the said adhesive composition is a sealing material with the high inhibitory effect of deterioration of a to-be-sealed thing.
- the sheet-like material (adhesive layer) formed from the adhesive composition of Comparative Example 1 had a high storage elastic modulus G ′ at 80 ° C. and resulted in inferior conformability.
- the sheet-like material (adhesive layer) formed from the adhesive composition of Comparative Example 2 produced a large amount of outgas and resulted in poor sealing properties.
- Production Example 1 (Production of gas barrier film) An ultraviolet curable acrylate resin composition (manufactured by JSR Corporation, product name) on a 50 ⁇ m thick polyethylene terephthalate (PET) film (manufactured by Toyobo Co., Ltd., product name “PET50A4300”) subjected to easy adhesion treatment on both sides “Opster Z7530”) was applied using a Meyer bar to form a coating film, and the coating film was dried at 70 ° C. for 1 minute.
- PET polyethylene terephthalate
- the coating film is cured by irradiating ultraviolet rays at an illuminance of 250 mW / cm 2 and a light amount of 170 mJ / cm 2 to form a primer layer having a thickness of 1000 nm. Formed.
- a coating agent having a solid content concentration of 10 mass% mainly composed of perhydropolysilazane manufactured by Merck Performance Materials, product name “Aquamica NL110-20”, solvent: xylene
- a spin coater manufactured by Mikasa Co., Ltd., product name “MS-A200”
- coating was performed at a rotation speed of 3000 rpm and a rotation time of 30 seconds.
- the said coating film was dried at 120 degreeC for 2 minute (s), and the polysilazane layer comprised from the polysilazane of thickness 150nm was formed on the said primer layer.
- a gas barrier layer having a thickness of 150 nm was formed by subjecting the surface of the formed polysilazane layer to a modification treatment by a plasma ion implantation method under the following conditions using a plasma ion implantation apparatus. This produced the gas barrier film which has a PET film and a gas barrier layer.
- Example 4 Using a heat laminator, the surface of the adhesive layer having a thickness of 12 ⁇ m on the release film of the laminate produced in Example 1 and the surface of the gas barrier layer having a thickness of 150 nm of the gas barrier film produced in Production Example 1 were used. At 60 ° C., a gas barrier laminate (1) was produced.
- Example 4 and Comparative Example 3 Using the above gas barrier laminate obtained in Example 4 and Comparative Example 3, the following interlayer adhesion was evaluated.
- the gas barrier laminate produced in Example 4 and Comparative Example 3 was cut into a size of 25 mm in length and 300 mm in width, the release film was removed, the surface of the exposed adhesive layer was pasted on a glass plate, and a heat laminator The test sample was prepared by pressure bonding at 60 ° C. The test sample was heated at 100 ° C. for 2 hours to cure the adhesive layer, and then allowed to stand for 24 hours in an environment of 23 ° C. and a relative humidity of 50%. Furthermore, after standing for 168 hours in an environment of a temperature of 85 ° C. and 85% RH (relative humidity), when the gas barrier laminate is peeled off from the glass plate under the condition of a peeling angle of 180 °, adhesion to the glass plate The presence or absence of transfer of the agent layer was confirmed.
- RH relative humidity
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Abstract
Description
しかし、有機EL素子には、時間の経過とともに、発光輝度、発光効率、発光均一性等の発光特性が低下し易いという問題があった。
この発光特性の低下の問題の原因として、酸素や水分等が有機EL素子の内部に浸入し、電極や有機層を劣化させることが考えられたため、封止材を用いて有機EL素子を封止し、酸素や水分の浸入を防ぐことが行われてきた。
封止材を用いて有機EL素子を封止する場合、封止材からアウトガスが発生すると有機EL素子を劣化させることから、低アウトガス性の封止材の開発が行われてきた。
特許文献1には、硬化遅延剤として用いるアゾール系化合物を用いた封止用組成物とすることで、低アウトガス性及び防湿性を有する硬化物を形成し得る旨が記載されている。
特許文献1では、記載の封止用組成物について、凹凸追従性の検討は行われていない。
そのため、低アウトガス性を有し、被封止物の劣化の抑制効果が高い封止材が求められている。
そのため、接着剤組成物には、ガスバリア層との層間密着性に優れた層の形成材料としての特性も要求されている。
[1]変性ポリオレフィン系樹脂(A)、及び多官能エポキシ化合物(B)を含有する接着剤組成物であって、
前記接着剤組成物から形成したシート状物が下記要件(I)及び(II)を満たす、接着剤組成物。
・要件(I):前記シート状物の80℃における貯蔵弾性率G’が0.3MPa以下である。
・要件(II):前記シート状物を120℃の環境下で20分間静置した際の、前記シート状物の1cm3当たり発生するアウトガス量が、20mg/cm3以下である。
[2]成分(A)が、酸変性ポリオレフィン系樹脂である、上記[1]に記載の接着剤組成物。
[3]成分(A)の含有量が、前記接着剤組成物の有効成分の全量に対して、15~70質量%である、上記[1]又は[2]に記載の接着剤組成物。
[4]成分(B)が、多官能脂環式エポキシ化合物及び多官能脂肪族エポキシ化合物から選ばれる1種以上である、上記[1]~[3]のいずれか一項に記載の接着剤組成物。
[5]成分(B)の含有量が、成分(A)100質量部に対して、25~200質量部である、上記[1]~[4]のいずれか一項に記載の接着剤組成物。
[6]さらに、粘着付与剤(C)を含有する、上記[1]~[5]のいずれか一項に記載の接着剤組成物。
[7]成分(C)の含有量が、成分(A)100質量部に対して、1~200質量部である、上記[6]に記載の接着剤組成物。
[8]さらに、イミダゾール系硬化触媒(D)を含有する、上記[1]~[7]のいずれか一項に記載の接着剤組成物。
[9]成分(D)の含有量が、成分(A)100質量部に対して、0.1~10質量部である、上記[8]に記載の接着剤組成物。
[10]さらに、シランカップリング剤(E)を含有する、上記[1]~[9]のいずれか一項に記載の接着剤組成物。
[11]成分(E)の含有量が、成分(A)100質量部に対して、0.01~10質量部である、上記[10]に記載の接着剤組成物。
[12]上記[1]~[11]のいずれか一項に記載の接着剤組成物から形成された接着剤層を有する、封止シート。
[13]さらに、基材層とガスバリア層とを備えたガスバリア性フィルムを有する、上記[12]に記載の封止シート。
[14]前記ガスバリア性フィルムのガスバリア層と、前記接着剤層とが直接積層した構成である、上記[13]に記載の封止シート。
[15]前記ガスバリア層が、高分子化合物を含み、改質処理が施された高分子層である、上記[13]又は[14]に記載の封止シート。
[16]有機EL素子、有機ELディスプレイ素子、液晶ディスプレイ素子、又は太陽電池素子を、上記[12]~[15]のいずれか一項に記載の封止シートで封止してなる、封止体。
本発明の接着剤組成物は、変性ポリオレフィン系樹脂(A)、及び多官能エポキシ化合物(B)を含有し、当該接着剤組成物から形成したシート状物が、下記要件(I)及び(II)を満たすものである。
・要件(I):前記シート状物の80℃における貯蔵弾性率G’が0.3MPa以下である。
・要件(II):前記シート状物を120℃の環境下で20分間静置した際の、前記シート状物の1cm3当たり発生するアウトガス量が、20mg/cm3以下である。
また、要件(II)で規定のとおり、前記シート状物の1cm3当たり発生し得るアウトガス量が20mg/cm3以下であるため、本発明の接着剤組成物は、低アウトガス性を有する封止材であるといえる。
つまり、本発明の接着剤組成物は、上記要件(I)及び(II)を満たすように調製されているため、優れた低アウトガス性及び凹凸追従性を有し、被封止物の劣化の抑制効果が高い封止材となり得る。
なお、本明細書において、要件(I)で規定する前記シート状物の貯蔵弾性率G’は、実施例に記載の方法により測定された値を意味する。
なお、本明細書において、要件(II)で規定する前記シート状物のアウトガス量は、実施例に記載の方法により測定された値を意味する。
・要件(III):前記シート状物のヘイズが2.0%以下である。
要件(III)で規定のとおり、前記シート状物のヘイズが2.0%以下であれば、当該接着剤組成物は、有機EL素子等の光学素子を封止する封止材として好適に使用され得る。
なお、本明細書において、要件(III)で規定する前記シート状物のヘイズは、実施例に記載の方法により測定された値を意味する。
上記要件(I)~(III)を満たす接着剤組成物を調製するためのより具体的な方法は、以下の詳述する各成分に関する記載のとおりである。
このような成分として、本発明の接着剤組成物は、さらに、粘着付与剤(C)、イミダゾール系硬化触媒(D)、並びに、シランカップリング剤(E)から選ばれる1種以上を含有することが好ましく、さらに、成分(C)、(D)、及び(E)を含有することがより好ましい。
なお、本明細書において、接着剤組成物の有効成分とは、接着剤組成物中に含まれる、物性に関与しない希釈溶媒を除いた成分を指す。
本発明の接着剤組成物は、変性ポリオレフィン系樹脂(A)を含有する。
本発明の接着剤組成物は、変性ポリオレフィン系樹脂(A)を含有することで、接着強度に優れる組成物とすると共に、膜厚が比較的薄いシート状物(接着剤層)の形成性を良好とすることができる。
なお、変性ポリオレフィン系樹脂(A)は、単独で用いてもよく、2種以上を併用してもよい。
また、ポリオレフィン樹脂とは、オレフィン系単量体に由来する繰り返し単位を有する重合体を指す。
なお、本発明において、当該ポリオレフィン樹脂は、オレフィン系単量体に由来する繰り返し単位のみから構成された重合体であってもよいし、オレフィン系単量体に由来の繰り返し単位と共に、オレフィン系単量体以外の単量体に由来する繰り返し単位とを有する共重合体であってもよい。
オレフィン系単量体以外の単量体としては、例えば、酢酸ビニル、(メタ)アクリル酸エステル、スチレン等が挙げられる。
官能基としては、カルボキシル基、カルボン酸無水物に由来の基、カルボン酸エステル基、水酸基、エポキシ基、アミド基、アンモニウム基、ニトリル基、アミノ基、イミド基、イソシアネート基、アセチル基、チオール基、エーテル基、チオエーテル基、スルホン基、ホスホン基、ニトロ基、ウレタン基、ハロゲン原子等が挙げられる。
これらの中でも、カルボキシル基、カルボン酸無水物に由来の基、カルボン酸エステル基、水酸基、アンモニウム基、アミノ基、イミド基、又はイソシアネート基が好ましく、カルボン酸無水物に由来の基、又はアルコキシシリル基がより好ましく、カルボン酸無水物に由来の基が更に好ましい。
使用する変性剤は、分子内に2種以上の官能基を有する化合物であってもよい。
これらは、単独で又は2種以上を併用してもよい。
これらの中でも、接着強度をより向上させると共に、上記要件(I)及び(II)を満たす接着剤組成物とする観点から、無水マレイン酸が好ましい。
市販品の酸変性ポリオレフィン系樹脂としては、例えば、アドマー(登録商標)(三井化学株式会社製)、ユニストール(登録商標)(三井化学株式会社製)、BondyRam(Polyram社製)、orevac(登録商標)(ARKEMA社製)、モディック(登録商標)(三菱化学株式会社製)等が挙げられる。
これらの不飽和シラン化合物は、単独で又は2種以上を併用してもよい。
なお、不飽和シラン化合物を主鎖であるポリオレフィン樹脂にグラフト重合させる場合の条件は、公知のグラフト重合の常法を採用すればよい。
市販品のシラン変性ポリオレフィン系樹脂としては、例えば、リンクロン(登録商標)(三菱化学株式会社製)等が挙げられるが、低密度ポリエチレン系のリンクロン、直鎖状低密度ポリエチレン系のリンクロン、超低密度ポリエチレン系のリンクロン、及びエチレン-酢酸ビニル共重合体系のリンクロンが好ましい。
変性ポリオレフィン系樹脂(A)の重量平均分子量が上記範囲にあることで、接着剤組成物中の変性ポリオレフィン系樹脂(A)の含有量が多い場合であっても、当該接着剤組成物からシート状に形成した際に、その形状の形状維持性が良好となる。
本発明の接着剤組成物は、多官能エポキシ化合物(B)を含有する。
本発明の接着剤組成物は、多官能エポキシ化合物(B)を含有することで、水蒸気遮断性に優れた封止材となり得る。
なお、多官能エポキシ化合物(B)は、単独で用いてもよく、2種以上を併用してもよい。
成分(B)としては、上記要件(I)及び(II)を満たす接着剤組成物とする観点から、エポキシ基を2つ有する2官能エポキシ化合物が好ましい。
上記観点から、芳香族エポキシ化合物の含有量は、成分(B)の全量(100質量%)に対して、好ましくは0~50質量%、より好ましくは0~20質量%、更に好ましくは0~10質量%、より更に好ましくは0~2質量%である。
また、要件(I)を満たす接着剤組成物とする観点から、25℃において液体である多官能エポキシ化合物(B1)の重量平均分子量(Mw)は、好ましくは4,000以下、より好ましくは3,700以下、更に好ましくは3,400以下である。
(B2)成分の多官能エポキシ化合物は、(B1)成分の多官能エポキシ化合物とは異なり、貯蔵弾性率低下効果をほとんど有しないと考えられる。一方で、接着剤組成物が(B2)成分を含有することで、接着剤層がシート形状を維持する性能が向上する。
このような傾向が存在する結果、(B2)成分は、(B1)成分と組み合わせて用いた場合、(B1)成分が有する貯蔵弾性率低下効果をさらに高めることができる。(B2)成分が存在することで、接着剤層のシート形状を維持する性能を保ちつつ、接着剤組成物中の(B)成分の含有量を増やすことができる。そのため、接着剤組成物中で(A)成分と(B)成分とで形成される相分離構造において、(B)成分の連続相の領域の割合が増加する。このような接着剤組成物から形成される接着剤層を昇温すると、(B)成分の連続相の領域が軟化するため、高い貯蔵弾性率低下効果が発現される。
したがって、本発明の接着剤組成物は、(B1)成分と(B2)成分の両方を含有することがより好ましい。
また、25℃において固体である多官能エポキシ化合物(B2)の重量平均分子量(Mw)は、好ましくは8,000以下、より好ましくは7,000以下である。
(B1)成分に対する(B2)成分の量が増えるに従って、接着剤組成物をシート状に成形したときに一定の形状が保たれ易くなる傾向がある。
本発明の接着剤組成物は、形成される封止材の形状維持性をより良好とする観点から、さらに、粘着付与剤(C)を含有することが好ましい。
これらの粘着付与剤(C)は、単独で用いてもよく、2種以上を併用してもよい。
これらの中でも、成分(C)としては、スチレン系樹脂が好ましく、スチレン系モノマーと脂肪族系モノマーとの共重合体がより好ましい。
なお、本明細書において、軟化点は、JIS K 5902に準拠して測定した値を意味する。
2種以上の複数の粘着付与剤を用いる場合、それら複数の粘着付与剤の軟化点の加重平均が、上記範囲に属することが好ましい。
本発明の接着剤組成物は、高温環境下でも優れた接着性を発現し得る接着剤組成物とする観点から、さらに、イミダゾール系硬化触媒(D)を含有することが好ましい。
これらのイミダゾール系硬化触媒(D)は、単独で用いてもよく、2種以上を併用してもよい。
これらの中でも、成分(D)としては、2-エチル-4-メチルイミダゾールが好ましい。
本発明の接着剤組成物は、常温及び高温環境下のいずれにおいても、優れた接着強度を有する封止体を形成し得る接着剤組成物とする観点から、さらに、シランカップリング剤(E)を含有することが好ましい。
具体的なシランカップリング剤(E)としては、例えば、ビニルトリメトキシシラン、ビニルトリエトキシシラン、メタクリロキシプロピルトリメトキシシラン等の重合性不飽和基含有ケイ素化合物;3-グリシドキシプロピルトリメトキシシラン、グリシドキシオクチルトリメトキシシラン、2-(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等のエポキシ構造を有するケイ素化合物;3-アミノプロピルトリメトキシシラン、N-(2-アミノエチル)-3-アミノプロピルトリメトキシシラン、N-(2-アミノエチル)-3-アミノプロピルメチルジメトキシシラン等のアミノ基含有ケイ素化合物;3-クロロプロピルトリメトキシシラン;3-イソシアネートプロピルトリエトキシシラン;等が挙げられる。
これらのシランカップリング剤(E)は、単独で用いてもよく、2種以上を併用してもよい。
本発明の接着剤組成物は、本発明の効果を損なわない範囲で、上述の成分(A)~(E)以外のその他の添加剤を含有してもよい。
その他の添加剤としては、用途に応じて適宜選択されるが、例えば、紫外線吸収剤、帯電防止剤、光安定剤、酸化防止剤、樹脂安定剤、充填剤、顔料、増量剤、軟化剤等の添加剤が挙げられる。
これらの添加剤は、単独で用いてもよく、2種以上を併用してもよい。
上記観点から、充填剤及び顔料の合計含有量としては、前記接着剤組成物の有効成分の全量(100質量%)に対して、好ましくは0~10質量%、より好ましくは0~5質量%、更に好ましくは0~1質量%、より更に好ましくは0~0.001質量%である。
希釈溶媒としては、有機溶媒の中から適宜選択することができるが、具体的には、ベンゼン、トルエン等の芳香族炭化水素系溶媒;酢酸エチル、酢酸ブチル等のエステル系溶媒;アセトン、メチルエチルケトン、メチルイソブチルケトン等のケトン系溶媒;n-ペンタン、n-ヘキサン、n-ヘプタン等の脂肪族炭化水素系溶媒;シクロペンタン、シクロヘキサン、メチルシクロヘキサン等の脂環式炭化水素系溶媒;等が挙げられる。
これらの溶媒は、単独で用いてもよく、2種以上を併用してもよい。
なお、溶媒の含有量は、塗布性等を考慮して適宜設定することができる。
本発明の封止シートは、上述の接着剤組成物から形成された接着剤層を有するものである。
接着剤層の厚さは、用途に応じて適宜設定されるが、好ましくは2~50μm、より好ましくは5~25μm、更に好ましくは10~20μmである。
そのため、本発明の封止シートが有する接着剤層についての80℃における貯蔵弾性率G’及びアウトガス量の好適範囲は、それぞれ、上述の要件(I)及び(II)の規定の範囲と同一である。
接着剤層を熱硬化させる際の条件は特に限定されないが、加熱温度は、通常80~200℃(好ましくは90~150℃)であり、加熱時間は、通常30分~12時間(好ましくは1~6時間)である。
・封止シート(α):2枚の剥離フィルムで、本発明の接着剤組成物から形成された接着剤層を挟持した構成を有する封止シート。
・封止シート(β):基材層及びガスバリア層を有するガスバリア性フィルムと、本発明の接着剤組成物から形成された接着剤層とを有する封止シート。なお、封止シート(β)においては、さらに剥離フィルムが接着剤層上に積層していてもよい。
なお、これらの封止シートは使用前の状態を表したものであり、本発明の封止シートを使用する際は、通常、剥離フィルムは剥離除去される。
剥離フィルム用基材としては、例えば、グラシン紙、コート紙、上質紙等の紙基材;これらの紙基材にポリエチレン等の熱可塑性樹脂をラミネートしたラミネート紙;ポリエチレンテレフタレート樹脂、ポリブチレンテレフタレート樹脂、ポリエチレンナフタレート樹脂、ポリプロピレン樹脂、ポリエチレン樹脂等から形成したプラスチックフィルム;等が挙げられる。
剥離剤としては、例えば、シリコーン系樹脂、オレフィン系樹脂、イソプレン系樹脂、ブタジエン系樹脂等のゴム系エラストマー、長鎖アルキル系樹脂、アルキド系樹脂、フッ素系樹脂等が挙げられる。
また、塗布性を良好とする観点から、接着剤組成物に上述の希釈溶媒を加えて、溶液の形態とすることが好ましい。
塗膜を乾燥させるときの乾燥条件としては、例えば、通常80~150℃で、30秒~5分間の乾燥処理を施すことが好ましい。
特に、ガスバリア層が、後述するような、高分子化合物を含み、改質処理が施された高分子層である場合には、一般的な接着剤層と当該ガスバリア層の間の層間密着性に劣ることがある。
しかしながら、本発明の接着剤組成物から形成された接着剤層は、変性ポリオレフィン樹脂(A)と共に多官能エポキシ樹脂(B)を含有することで、このような高分子層であるガスバリア層との層間密着性に優れたものとなり得る。
封止シート(β)の水蒸気透過率が0.1g/m2/day以下であれば、透明基板上に形成された有機EL素子等の素子内部に酸素や水分等の浸入を抑え、電極や有機層が劣化することを効果的に抑制することができる。
なお、本明細書において、水蒸気透過率は、一般的なガス透過率測定装置を用いて測定することができる。当該ガス透過率測定装置としては、例えば、mocon社製の製品名「PERMATRAN」等が挙げられる。
また、封止シート(β)の上記の水蒸気透過率は、封止シート(β)を使用に供される状態で測定した値であり、すなわち、例えば、封止シート(β)が剥離フィルムを備える場合には、当該剥離フィルムを除去して測定した値である。
当該樹脂成分としては、ポリイミド、ポリアミド、ポリアミドイミド、ポリフェニレンエーテル、ポリエーテルケトン、ポリエーテルエーテルケトン、ポリオレフィン、ポリエステル、ポリカーボネート、ポリスルホン、ポリエーテルスルホン、ポリフェニレンスルフィド、ポリアリレート、アクリル系樹脂、シクロオレフィン系ポリマー、芳香族系重合体、ポリウレタン系ポリマー等が挙げられる。
これらの樹脂成分は、単独で用いてもよく、2種以上を併用してもよい。
ガスバリア性フィルムが有する基材層の厚さは、特に制限はないが、取り扱い易さの観点から、好ましくは0.5~500μm、より好ましくは1~200μm、更に好ましくは5~100μmである。
高分子化合物を含み、改質処理が施された高分子層は、柔軟性に優れているため、ガスバリア層が当該高分子層であることで、屈曲への耐性に優れたガスバリア性積層体とすることができる。
これらの高分子化合物は、単独で用いてもよく、2種以上を併用してもよい。
これらの中でも、優れたガスバリア性を有するガスバリア層を形成できるとの観点から、高分子層に含まれる高分子化合物としては、ケイ素含有高分子化合物が好ましく、ポリシラザン系化合物がより好ましい。
ポリシラザン系化合物の数平均分子量としては、好ましくは100~50,000である。
Rx、Ry、Rzは、それぞれ独立して、水素原子、無置換若しくは置換基を有するアルキル基、無置換若しくは置換基を有するシクロアルキル基、無置換若しくは置換基を有するアルケニル基、無置換若しくは置換基を有するアリール基又はアルキルシリル基を表す。
これらの中でも、Rx、Ry、Rzとしては、水素原子、炭素数1~6のアルキル基、又はフェニル基が好ましく、水素原子がより好ましい。
なお、ガスバリア層に含まれる高分子化合物としては、前記一般式(1)中のRx、Ry、Rzが全て水素原子である無機ポリシラザンであってもよく、Rx、Ry、Rzの少なくとも1つが水素原子以外の基である有機ポリシラザンであってもよい。
また、ポリシラザン系化合物として、ポリシラザン変性物を用いることもでき、また、市販品を用いることもできる。
他の成分としては、例えば、硬化剤、他の高分子、老化防止剤、光安定剤、難燃剤等が挙げられる。
前記高分子層中の高分子化合物の含有量は、より優れたガスバリア性を有するガスバリア層とする観点から、高分子層中の成分の全量(100質量%)に対して、好ましくは50~100質量%、より好ましくは70~100質量%、更に好ましくは80~100質量%である。
本発明においては、高分子層の厚さがナノオーダーであっても、充分なガスバリア性を有する封止シートを得ることができる。
イオン注入処理は、後述するように、高分子層にイオンを注入して、高分子層を改質する方法である。
プラズマ処理は、高分子層をプラズマ中に晒して、高分子層を改質する方法である。例えば、特開2012-106421号公報に記載の方法に従って、プラズマ処理を行うことができる。
放射線照射処理は、高分子層に放射線を照射して高分子層を改質する方法である。放射線は、高分子層の結合構造を変化させる効果の高い短波長のものが好ましく、紫外線、特に真空紫外光を用いることが好ましい。例えば、特開2013-226757号公報に記載の方法に従って、真空紫外光改質処理を行うことができる。
これらの中でも、高分子層の表面を荒らすことなく、その内部まで効率よく改質し、よりガスバリア性に優れるガスバリア層を形成できるとの観点から、高分子層の改質処理としては、イオン注入処理が好ましい。
これらのイオンは、単独で用いてもよく、2種以上を併用してもよい。
これらの中でも、より簡便にイオンを注入することができ、特に優れたガスバリア性を有するガスバリア層が得られるとの観点から、アルゴン、ヘリウム、ネオン、クリプトン、キセノン等の希ガスのイオンが好ましく、アルゴンイオンがより好ましい。
プラズマイオン注入法は、例えば、プラズマ生成ガスを含む雰囲気下でプラズマを発生させ、イオンを注入する層に負の高電圧パルスを印加することにより、該プラズマ中のイオン(陽イオン)を、イオンを注入する層の表面部に注入して行うことができる。
また、封止シート(α)を製造した後、封止シート(α)が有する2枚の剥離フィルムのうち1枚を剥離し、表出した接着剤層とガスバリア性フィルムのガスバリア層とを貼着することで、封止シート(β)を製造することもできる。この場合、封止シート(α)が、異なる剥離力を有する2枚の剥離フィルムを有する場合には、取扱い性の観点から、剥離力の小さい方の剥離フィルムを剥離するのが好ましい。
当該封止シートにおいては、ガスバリア層と接着剤層とを直接積層した構成とすることが好ましい。
本発明の封止体は、被封止物が、本発明の封止シートで封止されてなるものである。
本発明の封止体としては、例えば、透明基板と、該透明基板上に形成された素子(被封止物)と、該素子を封止するための封止材とを備えるものであって、前記封止材が、本発明の封止シートの接着剤層であるものが挙げられる。
具体的には、石英やガラス等の透明無機材料;ポリエチレンテレフタラート、ポリエチレンナフタラート、ポリカーボネート、ポリスチレン、ポリエチレン、ポリプロピレン、ポリフェニレンスルフィド、ポリフッ化ビニリデン、アセチルセルロース、ブロム化フェノキシ、アラミド類、ポリイミド類、ポリスチレン類、ポリアリレート類、ポリスルホン類、ポリオレフィン類等の透明プラスチック、前述したガスバリア性フィルム;が挙げられる。
透明基板の厚さは特に制限されず、光の透過率や、素子内外を遮断する性能を勘案して、適宜選択することができる。
つまり、本発明の封止体は、有機EL素子、有機ELディスプレイ素子、液晶ディスプレイ素子、又は太陽電池素子を、本発明の封止シートで封止してなるものであることが好ましい。
次いで、この接着剤層を硬化させることにより、本発明の封止体を製造することができる。
なお、変性ポリオレフィン系樹脂及び多官能エポキシ化合物の重量平均分子量(Mw)は、以下の方法により測定した値である。
<変性ポリオレフィン系樹脂の重量平均分子量(Mw)>
変性ポリオレフィン系樹脂の重量平均分子量(Mw)は、ゲル浸透クロマトグラフ(GPC)装置(東ソー株式会社製、製品名「HLC-8320」)を用いて、下記の条件下で測定し、標準ポリスチレンの重量平均分子量に換算した値を用いた。
(測定条件)
・測定試料:サンプル濃度1質量%のテトラヒドロフラン溶液
・カラム:「TSK gel Super HM-H」を2本、「TSK gel Super H2000」を1本(いずれも東ソー株式会社製)、順次連結したもの
・カラム温度:40℃
・展開溶媒:テトラヒドロフラン
・流速:0.60mL/min
<多官能エポキシ化合物の重量平均分子量(Mw)>
多官能エポキシ化合物の重量平均分子量(Mw)は、上記のゲル浸透クロマトグラフ(GPC)装置を用いて、上記の条件下で測定し、複数観察されるピークのうち、面積が最大であるもののピークトップの保持時間に対応する標準ポリスチレンの重量平均分子量に換算したものである。
(1)接着剤組成物の調製
下記に示す各成分を、表1に記載の配合量(有効成分比)にて添加し、メチルエチルケトンで希釈して、実施例1~2及び比較例1~2においては、有効成分濃度30質量%の接着剤組成物をそれぞれ調製し、実施例3においては、有効成分濃度25質量%の接着剤組成物を調製した。
使用した各成分の詳細は、以下のとおりである。
・変性ポリオレフィン系樹脂:三井化学株式会社製、製品名「ユニストールH-200」、酸変性α-オレフィン重合体、25℃において固体、重量平均分子量(Mw)=52,000。
・多官能エポキシ化合物(1):三菱化学株式会社製、製品名「YX8034」、水添ビスフェノールAジグリシジルエーテル、エポキシ当量=270g/eq、25℃において液体、重量平均分子量(Mw)=3,200。
・多官能エポキシ化合物(2):三菱化学株式会社製、製品名「YL980」、ビスフェノールAジグリシジルエーテル、25℃において液体、エポキシ当量=180~190g/eq、重量平均分子量(Mw)=2,400。
・多官能エポキシ化合物(3):共栄社化学株式会社製、製品名「エポライト4000」、水添ビスフェノールAジグリシジルエーテル、25℃において液体、エポキシ当量=215~245g/eq、重量平均分子量(Mw)=800。
・多官能エポキシ化合物(4):三菱化学株式会社製、製品名「YX8000」、水添ビスフェノールAジグリシジルエーテル、25℃において液体、エポキシ当量=205g/eq、重量平均分子量(Mw)=1,400。
・多官能エポキシ化合物(5):三菱化学株式会社製、製品名「YX8040」、水添ビスフェノールAジグリシジルエーテル、25℃において固体、エポキシ当量=1100g/eq、重量平均分子量(Mw)=4,200。
・粘着付与剤:三井化学株式会社製、製品名「FTR6100」、スチレン系モノマーと脂肪族系モノマーとの共重合体、軟化点=95℃。
・イミダゾール系硬化触媒:四国化成工業株式会社製、製品名「キュアゾール2E4MZ」、2-エチル-4-メチルイミダゾール。
・シランカップリング剤:信越化学工業株式会社製、製品名「KBM-4803」、グリシドキシオクチルトリメトキシシラン。
剥離フィルム(リンテック株式会社製、製品名「SP-PET382150」)の剥離処理面上に、調製した接着剤組成物を塗布して塗膜を形成し、当該塗膜を100℃で2分間乾燥し、厚さ12μmのシート状物(接着剤層)を形成し、剥離フィルム及びシート状物(接着剤層)からなる積層体を得た。
また、上記(2)の手順と同様に作製した積層体のシート状物である接着剤層の表面上に、厚さ25μmのポリエチレンテレフタレートフィルム(三菱ケミカル株式会社製、製品名「T600E」)を積層し、剥離フィルム、接着剤層、及び基材をこの順で積層した基材付き封止シートを得た。
実施例又は比較例で作製した積層体から剥離フィルムを除去したシート状物(接着剤層)を複数重ね合わせ、ヒートラミネーターを用いて、60℃で加熱圧縮し、厚さ1mmの積層体を得た。
この積層体を試験サンプルとして、粘弾性測定装置(Anton Paar社製、製品名「Physica MCR301」)を用いて、周波数1Hzの条件下、温度範囲23~150℃における、硬化前の当該積層体の貯蔵弾性率G’を測定した。測定した80℃における貯蔵弾性率G’の値を表1に示す。
実施例又は比較例で作製した積層体のシート状物の表面を、ガラス板の平坦面に静置し、ヒートラミネーターを用いて、60℃で接着し、積層体の剥離フィルムを除去して、試験サンプルを得た。
この試験サンプルを、120℃の環境下で、20分間静置した際にシート状物から発生したアウトガス量を、下記の装置を用いて測定した。
・装置:ガスクロマトグラフ質量分析計(株式会社島津製作所製、製品名「GCMSQP2010」)。
・カラム:5MS系カラム(株式会社島津製作所製、製品名「SH-Rtx(登録商標)-5MS」、5%ジフェニル/95%ジメチルポリシロキサン)。
・検量線:トルエン。
上述の「シート状物のアウトガス量」の測定で使用した前記試験サンプルを、100℃の環境下で2時間静置し、シート状物を硬化させた後、この硬化したシート状物のヘイズを、JIS K7136に準拠して測定した。
ガラス基板上に、疑似デバイスとして、厚さ10μmのポリエチレンテレフタレートの小片を静置した。そして、実施例及び比較例で作製した基材付き封止シートの剥離フィルムを除去し、表出した接着剤層を、ガラス基板上の疑似デバイスが完全に覆われるようにして、ガラス基板及び擬似デバイス上に積層し、ヒートラミネーターを用いて80℃で封止し、次いで80℃、0.5MPaで20分間の加圧処理を施した。その上で、100℃の環境下で2時間加熱し、接着剤層を硬化させた。
光学顕微鏡を用いて、擬似デバイスと硬化後の接着剤層との境界部分を平面視で観察し、以下のとおり、擬似デバイスと接着剤層との間に隙間の存在の有無によって、シート状物の凹凸追従性を評価した。
A:擬似デバイスと接着剤層との間に隙間は無いため、凹凸追従性は良好である。
F:擬似デバイスと接着剤層との間に隙間が確認されるため、凹凸追従性が劣る。
(i)有機EL素子の作製
陽極として酸化インジウムスズ(ITO)膜(厚さ:100nm、シート抵抗:50Ω/□)が成膜されたガラス基板を用いて、以下の方法により有機EL素子を作製した。
前記ガラス基板のITO膜上に、N,N’-ビス(ナフタレン-1-イル)-N,N’-ビス(フェニル)-ベンジジン)(Luminescence Technology社製)を速度0.1~0.2nm/分の速度で蒸着させ、厚さ50nmの正孔輸送層を形成した。
そして、形成した正孔輸送層上に、トリス(8-ヒドロキシ-キノリネート)アルミニウム(Luminescence Technology社製)を0.1~0.2nm/分の速度で蒸着させ、厚さ50nmの発光層を形成した。
さらに、形成した発光層上に、フッ化リチウム(LiF)(高純度化学研究所社製)を0.1nm/分の速度で蒸着させ、厚さ4nmの電子注入層を形成した。
最後に、形成した電子注入層上に、アルミニウム(Al)(高純度化学研究所社製)を0.1nm/分の速度で蒸着させ、厚さ100nmの陰極を形成し、有機EL素子を得た。
なお、蒸着時の真空度は、全て1×10-4Pa以下であった。
実施例及び比較例で作製した積層体の接着剤層の表面を、金属箔フィルムに重ねて、ヒートラミネーターを用いて、40℃で接着した。
そして、当該積層体の剥離フィルムの除去し、表出した接着剤層を、ガラス基板上に形成された有機EL素子を覆うように積層し、ヒートラミネーターを用いて、40℃で接着し、次いで、100℃で2時間加熱して、接着剤層を硬化させ、有機EL素子を封止した封止体であるボトムエミッション型の電子デバイスを得た。
作製した電子デバイスを、85℃、85%RH(相対湿度)の環境下で、240時間静置した後、電子デバイスを起動させ、有機EL素子のダークスポット(非発光箇所)の面積S1を測定した。
上記環境下に静置する前の有機EL素子のダークスポットの面積S0も予め測定の上、下記式(1)から、ダークスポットの拡大率を算出し、以下の基準に基づき、封止シートの封止性を評価した。
[ダークスポットの拡大率(%)]=(S1/S0)×100 ・・・(1)
A:ダークスポットの拡大率が150%未満である。
F:ダークスポットの拡大率が150%以上である。
なお、ダークスポットの拡大率は、値が大きいほど、電極や有機層の劣化が進行していることを意味する。
一方、比較例1の接着剤組成物から形成したシート状物(接着剤層)は、80℃における貯蔵弾性率G’が高く、凹凸追従性が劣る結果となった。
また、比較例2の接着剤組成物から形成したシート状物(接着剤層)は、発生するアウトガス量が多く、封止性も劣る結果となった。
両面に易接着処理が施された、厚さ50μmのポリエチレンテレフタレート(PET)フィルム(東洋紡株式会社製、製品名「PET50A4300」)上に、紫外線硬化型アクリレート樹脂組成物(JSR株式会社製、製品名「オプスターZ7530」)を、マイヤーバーを用いて塗布して塗膜を形成し、当該塗膜を70℃で1分間乾燥させた。そして、無電極UVランプシステム(ヘレウス株式会社製)を用いて、照度250mW/cm2、光量170mJ/cm2で紫外線を照射して、当該塗膜を硬化させて、厚さ1000nmのプライマー層を形成した。
そして、形成した前記プライマー層上に、ペルヒドロポリシラザンを主成分とする固形分濃度10質量%のコーティング剤(メルクパフォーマンスマテリアルズ社製、製品名「アクアミカNL110-20」、溶媒:キシレン)を、スピンコーター(ミカサ株式会社製、製品名「MS-A200」)を用いて、回転数3000rpm、回転時間30秒にて塗布して塗膜を形成した。そして、当該塗膜を120℃で2分間乾燥させ、前記プライマー層上に、厚さ150nmのポリシラザンから構成されたポリシラザン層を形成した。
次いで、形成した前記ポリシラザン層の表面に対して、プラズマイオン注入装置を用いて、下記条件にて、プラズマイオン注入法による改質処理を施すことで、厚さ150nmのガスバリア層を形成した。これにより、PETフィルム及びガスバリア層を有するガスバリア性フィルムを作製した。
(プラズマイオン注入の処理条件)
・チャンバー内圧:0.2Pa
・プラズマ生成ガス:アルゴン
・ガス流量:100sccm
・RF出力:1000W
・RF周波数:1000Hz
・RFパルス幅:50μ秒
・RF delay:25n秒
・DC電圧:-6kV
・DC周波数:1000Hz
・DCパルス幅:5μ秒
・DC delay:50μ秒
・Duty比:0.5%
・処理時間:200秒
実施例1で作製した積層体の剥離フィルム上の厚さ12μmの接着剤層の表面と、製造例1で作製したガスバリア性フィルムの厚さ150nmのガスバリア層の表面とを、ヒートラミネーターを用いて、60℃で貼り合わせ、ガスバリア性積層体(1)を作製した。
上述の変性ポリオレフィン系樹脂(三井化学株式会社製、製品名「ユニストールH-200」、酸変性α-オレフィン重合体、重量平均分子量(Mw)=52,000)のみを、メチルエチルケトンで希釈した、有効成分濃度30質量%の接着剤組成物を調製した。
そして、上記と同じ剥離フィルムの剥離処理面上に、調製した前記接着剤組成物を塗布し塗膜を形成し、当該塗膜を100℃で2分間乾燥して、厚さ12μmの接着剤層を形成した。
次いで、当該接着剤層の表面と、製造例1で作製したガスバリア性フィルムの厚さ150nmのガスバリア層の表面とを、ヒートラミネーターを用いて、60℃で貼り合わせ、ガスバリア性積層体(2)を作製した。
[層間密着性]
実施例4及び比較例3で作製したガスバリア性積層体を縦25mm×横300mmの大きさに裁断し、剥離フィルムを除去し、表出した接着剤層の表面をガラス板に貼付し、ヒートラミネーターを用いて、60℃で圧着し、試験サンプルを作製した。そして、この試験サンプルを、100℃で2時間加熱して、接着剤層を硬化させた後、23℃、相対湿度50%の環境下で24時間静置した。
さらに、温度85℃、85%RH(相対湿度)の環境下で168時間静置した後、剥離角度180°の条件で、ガスバリア性積層体をガラス板から剥離した際に、ガラス板への接着剤層の転着の有無を確認した。
一方、比較例3のガスバリア性積層体(2)においては、ガラス板への接着剤層の転着が確認されたため、接着剤層とガスバリア層との層間密着性に問題がある結果となった。
Claims (16)
- 変性ポリオレフィン系樹脂(A)、及び多官能エポキシ化合物(B)を含有する接着剤組成物であって、
前記接着剤組成物から形成したシート状物が下記要件(I)及び(II)を満たす、接着剤組成物。
・要件(I):前記シート状物の80℃における貯蔵弾性率G’が0.3MPa以下である。
・要件(II):前記シート状物を120℃の環境下で20分間静置した際の、前記シート状物の1cm3当たり発生するアウトガス量が、20mg/cm3以下である。 - 成分(A)が、酸変性ポリオレフィン系樹脂である、請求項1に記載の接着剤組成物。
- 成分(A)の含有量が、前記接着剤組成物の有効成分の全量に対して、15~70質量%である、請求項1又は2に記載の接着剤組成物。
- 成分(B)が、多官能脂環式エポキシ化合物及び多官能脂肪族エポキシ化合物から選ばれる1種以上である、請求項1~3のいずれか一項に記載の接着剤組成物。
- 成分(B)の含有量が、成分(A)100質量部に対して、25~200質量部である、請求項1~4のいずれか一項に記載の接着剤組成物。
- さらに、粘着付与剤(C)を含有する、請求項1~5のいずれか一項に記載の接着剤組成物。
- 成分(C)の含有量が、成分(A)100質量部に対して、1~200質量部である、請求項6に記載の接着剤組成物。
- さらに、イミダゾール系硬化触媒(D)を含有する、請求項1~7のいずれか一項に記載の接着剤組成物。
- 成分(D)の含有量が、成分(A)100質量部に対して、0.1~10質量部である、請求項8に記載の接着剤組成物。
- さらに、シランカップリング剤(E)を含有する、請求項1~9のいずれか一項に記載の接着剤組成物。
- 成分(E)の含有量が、成分(A)100質量部に対して、0.01~10質量部である、請求項10に記載の接着剤組成物。
- 請求項1~11のいずれか一項に記載の接着剤組成物から形成された接着剤層を有する、封止シート。
- さらに、基材層とガスバリア層とを備えたガスバリア性フィルムを有する、請求項12に記載の封止シート。
- 前記ガスバリア性フィルムのガスバリア層と、前記接着剤層とが直接積層した構成である、請求項13に記載の封止シート。
- 前記ガスバリア層が、高分子化合物を含み、改質処理が施された高分子層である、請求項13又は14に記載の封止シート。
- 有機EL素子、有機ELディスプレイ素子、液晶ディスプレイ素子、又は太陽電池素子を、請求項12~15のいずれか一項に記載の封止シートで封止してなる、封止体。
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WO2018221571A1 (ja) * | 2017-05-31 | 2018-12-06 | リンテック株式会社 | 接着シート、及び封止体 |
WO2018221572A1 (ja) * | 2017-05-31 | 2018-12-06 | リンテック株式会社 | 接着剤組成物、接着シート、及び封止体 |
WO2018221574A1 (ja) * | 2017-05-31 | 2018-12-06 | リンテック株式会社 | 接着剤組成物、接着シート、及び封止体 |
WO2018221573A1 (ja) * | 2017-05-31 | 2018-12-06 | リンテック株式会社 | 接着剤組成物、接着シート、及び封止体 |
WO2019189617A1 (ja) * | 2018-03-28 | 2019-10-03 | リンテック株式会社 | 樹脂組成物、封止シート及び封止体 |
CN112334507A (zh) * | 2018-06-15 | 2021-02-05 | 琳得科株式会社 | 树脂组合物、密封片材和密封体 |
CN113506848A (zh) * | 2018-05-24 | 2021-10-15 | 大日本印刷株式会社 | 自发光型显示体用或直下型背光源用的密封材料片、自发光型显示体、直下型背光源 |
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TWI742153B (zh) | 2021-10-11 |
JPWO2018047868A1 (ja) | 2018-09-13 |
CN109790427A (zh) | 2019-05-21 |
JP6512562B2 (ja) | 2019-05-15 |
CN109790427B (zh) | 2021-08-20 |
KR20190046839A (ko) | 2019-05-07 |
JP6329330B1 (ja) | 2018-05-23 |
KR102348192B1 (ko) | 2022-01-06 |
JP2018197336A (ja) | 2018-12-13 |
TW201816047A (zh) | 2018-05-01 |
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