WO2018184151A1 - Light cure epoxy composition - Google Patents

Light cure epoxy composition Download PDF

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Publication number
WO2018184151A1
WO2018184151A1 PCT/CN2017/079452 CN2017079452W WO2018184151A1 WO 2018184151 A1 WO2018184151 A1 WO 2018184151A1 CN 2017079452 W CN2017079452 W CN 2017079452W WO 2018184151 A1 WO2018184151 A1 WO 2018184151A1
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WO
WIPO (PCT)
Prior art keywords
group
epoxy resin
composition according
aromatic
methyl
Prior art date
Application number
PCT/CN2017/079452
Other languages
French (fr)
Inventor
Chunfu Chen
Bin Li
Choc WANG
Shuichi Iwasaki
Masao Kanari
Original Assignee
Henkel Ag & Co. Kgaa
Henkel (China) Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Henkel Ag & Co. Kgaa, Henkel (China) Co., Ltd. filed Critical Henkel Ag & Co. Kgaa
Priority to PCT/CN2017/079452 priority Critical patent/WO2018184151A1/en
Priority to CN201780090421.XA priority patent/CN110582540B/en
Priority to TW107111561A priority patent/TWI768023B/en
Publication of WO2018184151A1 publication Critical patent/WO2018184151A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • 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
    • C08L83/06—Polysiloxanes containing silicon bound to oxygen-containing groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • 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
    • C08G59/02—Polycondensates containing more than one epoxy group per molecule
    • 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
    • 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • 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

Definitions

  • the present invention relates to a light curable composition
  • a light curable composition comprising an epoxy resin component, multifunctional epoxy silane oligomer and a cationic photoinitiator.
  • Compositions according to the present invention provide good adhesive properties even under autoclave testing conditions.
  • thermosetting-type epoxy resins are used as adhesives.
  • Cationically photocurable epoxy resins have been developed for various applications.
  • This kind of epoxy resin compositions are advantageous because they provide cured products having comparable physical properties to thermosetting based compositions. Meaning that they are less inhibited by oxygen than a radical UV curable composition. In addition, they exhibit a smaller shrinkage than a radical UV curable composition. Therefore, these kind of compositions have been used in various well-known applications such as sealing of a liquid crystal display, lamination of a digital video disk, and sealing of a device package.
  • CMOS complementary metal-oxide-semiconductor
  • a device is placed in plastic or ceramic packages, and then the upper part is sealed with a glass plate by UV curable type of adhesives.
  • These adhesives have to have, in addition to the sealing and adhesive property with glass, excellent moisture resistance, water resistance, and storage stability in high and low temperatures.
  • Thermally curable epoxy resin compositions can be cured by cationic polymerization by the application of heat.
  • Such compositions comprise an alicyclic epoxy resin and/or bisphenol type epoxy resin as an epoxy resin, a photo-cationic polymerization initiator and/or thermo-cationic polymerization initiator as a curing agent, and at least one organosilicon compound as an additive.
  • the organosilicon compound produces a silanol group upon light irradiation and/or heating and/or hydrolysis.
  • Prior art also discloses a cationically curable epoxy resin composition
  • a cationically curable epoxy resin composition comprising: a) an epoxy resin component; b) a cationic photo-initiator; c) a cationic thermal-initiator; and d) a filler selected from the group consisting of oxides, hydroxides and carbonates containing a Group II element in the long periodic table.
  • This kind of cationically curable epoxy resin compositions are especially useful as an adhesive when at least one of two materials to be attached is a glass.
  • a light curable cationic epoxy composition has no oxygen inhibition issue and the composition has very low cure shrinkage. Therefore, this kind of compositions have been used as light cure adhesives or sealants in optical applications.
  • light curable cationic epoxy composition has higher reliability performance even at high temperature and high humidity conditions.
  • these light curable cationic epoxy compositions cannot withstand higher reliability requirements, i.e. autoclave conditions (higher than 100 °C with pressure applied) .
  • the present invention relates to a light curable composition
  • a light curable composition comprising a) an epoxy resin component; b) an epoxy silane oligomer having a general structure (1) :
  • n is an integer from 1 to 500;
  • R 1 is selected from the group consisting of C1-C10 alkyl group and aromatic group;
  • R 2 and R 3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group;
  • m is integer from 3 to 500;
  • R 4 , R 5 and R 6 are same or different and independently selected from the group consisting of hydrogen; and -Si (OR 7 ) 3 , wherein R 7 is selected from the group consisting of hydrogen, methyl and ethyl;
  • R 8 , R 9 and R 10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group;
  • the present invention also relates to a cured product of a composition according to the present invention.
  • the present invention further encompasses use of a composition according to the present invention as an adhesive or a sealant.
  • the present invention provides a light curable composition
  • n is an integer from 1 to 500;
  • R 1 is selected from the group consisting of C1-C10 alkyl group and aromatic group
  • R 2 and R 3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group;
  • m is integer from 3 to 500;
  • R 4 , R 5 and R 6 are same or different and independently selected from the group consisting of hydrogen; and -Si (OR 7 ) 3 , wherein R 7 is selected from the group consisting of hydrogen, methyl and ethyl;
  • R 8 , R 9 and R 10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group;
  • the light curable composition according to the present invention comprises an epoxy resin component.
  • the suitable epoxy resin component may contain only one kind of epoxy resin or it may contain a mixture of two or more different kind of epoxy resins.
  • the epoxy resin component according to the present invention comprises preferably an aromatic-ring containing epoxy resin having at least one epoxy group in one molecule.
  • the suitable aromatic-ring containing epoxy resin having at least one epoxy group in one molecule for use in the present invention is selected from the group consisting of bisphenol-Aepoxy resins, bisphenol-F epoxy resins and bisphenol-Sepoxy resins, phenol novolac epoxy resins, cresol novolac epoxy resins, biphenyl epoxy resins and mixtures thereof.
  • Aromatic-ring containing epoxy resins having at least one epoxy group in one molecule are preferred because they provide better thermal and humidity resistance (they have relatively high Tg values and provides relatively low absorbance during PCT testing (pressure cooker test) ) .
  • Suitable commercially available epoxy resins for use in the present invention include, but are not limited to D. E. R. 331 and D. E. R. 383 from Olin Corporation.
  • a composition according to the present invention contains an epoxy resin component from 20 to 98%by weight by of total weight of the composition, preferably from 40 to 97%, more preferably from 65 to 95%and even more preferably from 75%to 90%.
  • Preferred range from 75%to 90% is desired because it provides ideal physical properties for the composition.
  • the quantity of an epoxy resin component is below 20%, the adhesion properties of the composition are poor, whereas the quantity greater than 98%leads to the decrease of the other desired features of the composition and in some cases this may lead to poor overall performance.
  • the main component of the epoxy resin component is an aromatic-ring containing epoxy resin, however, in some embodiments, the epoxy resin component may also comprise an alicyclic epoxy resin.
  • the use of the alicyclic epoxy resin in combination with aromatic-ring containing epoxy resin having at least one epoxy group in one molecule is found to increase the curing rate of the epoxy resin component according to the present invention. Furthermore, this combination is effective to cure within a short period of UV radiation. While it is known in that the use of alicyclic epoxy resin increases curing rate of UV cationic system, it also deteriorates the adhesive properties of the composition. On the contrary, the use of the epoxy resin component as defined herewith increases the curing rate while maintaining good adhesive properties.
  • Suitable alicyclic epoxy resin for use in the present invention is selected from the group consisting of
  • a composition according to the present invention may comprise an alicyclic epoxy resin from 2 to 50%by weight of the total weight of the composition, preferably from 4 to 45%and more preferably from 5 to 40 %.
  • Suitable commercially available alicyclic epoxy resin for use in the present invention include, but are not limited to Celloxide 2021 P and Celloxide 2018 from Daicel Corporation; Syna Epoxy 21 and Syna Epoxy 28 from Synasia Inc. .
  • the epoxy resin component according to the present invention may further comprise hydrogenated bisphenol type epoxy resins and dicyclopentadiene type epoxy resins.
  • Hydrogenated bisphenol epoxy resins are compounds obtainable by hydrogenating benzene-rings in bisphenol epoxy resins such as bisphenol-Aepoxy resins, bisphenol-F epoxy resins, bisphenol-Sepoxy resins and the like. The use of these kind of epoxy resins as part of the epoxy resin component are found to increase the curing rate of the epoxy resin component remarkably and be effective to cure it with short period of UV radiation.
  • a composition according to the present invention comprises an epoxy silane oligomer.
  • the epoxy silane oligomer used in the present invention is a multifunctional epoxy silane oligomer.
  • multifunctional epoxy silane oligomer is meant herein an oligomer, which has more than one silane group and more than one epoxy group in a molecule.
  • a multifunctional epoxy silane oligomer is used in the composition according to the present invention in order to improve the adhesion properties especially to inorganic substrates.
  • Suitable epoxy silane oligomer for use in the present invention has a general structure (1) :
  • n is an integer from 1 to 500, preferably from 1 to 300 and more preferably from 1 to 200;
  • R 1 is selected from the group consisting of C1-C10 alkyl group and aromatic group; preferably R 1 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, and more preferably R 1 is propyl group;
  • R 2 and R 3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group;
  • R 2 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, and more preferably R 2 is methyl group;
  • R 3 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, more preferably R 3 is methyl group;
  • m is integer from 3 to 500, preferably from 3 to 300, and more preferably from 3 to 200;
  • R 4 , R 5 and R 6 are same or different and independently selected from the group consisting of hydrogen; and -Si (OR 7 ) 3 , wherein R 7 is selected from the group consisting of hydrogen, methyl and ethyl;
  • R 4 , R 5 and R 6 are same or different and independently selected from the group consisting of hydrogen; and -Si (OR 7 ) 3 , wherein R 7 is selected from the group consisting of hydrogen, methyl and ethyl, preferably R 7 is methyl or ethyl, and wherein functional group equivalent of –Si (OR 7 ) 3 to is 1 to 3;
  • o is integer from 3 to 500, preferably from 3 to 300, more preferably from 3 to 200;
  • R 8 , R 9 and R 10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group;
  • R 8 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, more preferably R 8 is methyl group;
  • R 9 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, more preferably R 9 is methyl group;
  • R 10 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably, more preferably R 10 is methyl group.
  • Preferred epoxy silane oligomers having preferred substituent groups are desired, because these epoxy silane oligomers provide in combination with the other ingredients, improved adhesive properties under autoclave testing conditions, and therefore, indicate a long time reliability performance. Improved adhesive properties are especially seen when performance of a composition according to the present invention comprising a multifunctional epoxy silane oligomer is compared to performance of a composition comprising a monofunctional epoxy silane oligomer. This is exemplified in the examples.
  • epoxy silane oligomer has a structure (1) :
  • n is an integer from 1 to 200; R 1 propyl group; R 2 is methyl group; and R 3 is methyl group.
  • epoxy silane oligomer has a structure (2) :
  • m is integer 3 to 200; R 4 , R 5 and R 6 are same or different and independently selected from the group consisting of hydrogen; and -Si (OR 7 ) 3 , wherein R 7 is methyl or ethyl, and wherein functional group equivalent of –Si (OR 7 ) 3 to is 1 to 3.
  • epoxy silane oligomer has a structure (3) :
  • o is integer from 3 to 200, R 8 is methyl group; R 9 is methyl group; and R 10 is methyl group.
  • Suitable commercially available epoxy silane oligomers for use in the present invention include, but are not limited to CoatOsil MP200 from Momentive Performance Materials Incorporation; X-12-981S and KR-516 from Shin-Etsu Chemical Co., Ltd. .
  • a composition according to the present invention comprises epoxy silane oligomer from 0.1 to 10%by weight of the total weight of the composition, preferably from 0.3 to 9%, more preferably from 1.0 to 8.5%and even more preferably from 3 to 7%.
  • composition according to the present invention comprises a cationic photo-initiator.
  • the suitable cationic photo-initiator for use in the present invention is a salt represented by formula A + B - which produces cationic active species by irritation of light.
  • the cation A + is selected from the group consisting of aromatic iodonium ions and aromatic sulfonium ions.
  • the anion B - is selected from the group consisting of SbF 6 - , PF 6 - , AsF 6 - and B (Aryl) 4 - , B (C 6 F 5 ) 4 - , B (C 6 F 4 OCF 3 ) 4 - and B (C 6 F 4 CF 3 ) 4 - .
  • the suitable aromatic iodonium ion for use in the present invention has the formula (9) :
  • groups Ar 1 and Ar 2 are same or different and independently to each other aromatic groups, phenyl groups, phenyl groups having substituent group.
  • the suitable aromatic sulfonium ion for use in the present invention has the formula (16) :
  • groups Ar 3 , Ar 4 and Ar 5 are same or different and independently to each other aryl groups, phenyl groups, phenyl groups having substituent group.
  • Preferred cationic photoinitiator is selected from the group consisting of triarylsulfonium hexafluoroantimonate salt (17) and a mixture of compound (18) and compound (19) . These preferred cationic photoinitiators provide best performance.
  • Suitable commercially available cationic photoinitiator for use in the present invention include, but is not limited to CPI 6976 from Aceto Corporation.
  • a composition according to the present invention comprises a cationic photoinitiator from 0.1 to 10%by weight of the total weight of the composition, preferably from 0.3 to 9%, more preferably from 1.0 to 8.5%and even more preferably from 2 to 5%.
  • a composition according to the present invention may further comprise an epoxy resin diluent.
  • the epoxy resin diluent is used to adjust the viscosity of the composition.
  • Suitable epoxy resin diluent for use in the present invention is selected from the group consisting of cyclohexanedimethanol diglycidyl ether, butyl glycidyl ether, 2-ethylhexyl glycidyl ether, 4-tert-butylphenol glycidyl ether, glycidyl methacrylate and tertiary carboxylic acid glycidyl esters, styrene oxide, phenyl glycidyl ether, cresyl glycidyl ether, p-s-butylphenyl glycidyl ether, nonylphenyl glycidyl ether, tetrahydrofurfuryl alcohol glycidyl ether and mixtures thereof, preferably said epoxy resin diluent is 4-tert-butylphenol glycidyl ether.
  • 4-tert-butylphenol glycidyl ether is preferred epoxy resin diluent because it provides a good thermal resistance while maintaining good dilution effect.
  • Suitable commercially available epoxy resin diluent for use in the present invention include, but are not limited to ED-509E and ED-509S from Adeka Corporation; DY-P from Huntsuman International LLC; and Erisys GE11 from CVC Thermoset Specialties.
  • a composition according to the present invention comprise from 1 to 20%by weight of total weight of the composition of an epoxy resin diluent, preferably from 5 to 15%and more preferably from 7 to 12%.
  • composition according to the present invention may further contain an aromatic monoglycidyl ether and/or an aromatic biglycidyl ether such as cresyl glycidyl ether, nonyl phenyl glycidyl ether and phenyl glycidyl ether, diglycidyl resorsinol ether and the mixtures thereof.
  • aromatic monoglycidyl ether and/or an aromatic biglycidyl ether such as cresyl glycidyl ether, nonyl phenyl glycidyl ether and phenyl glycidyl ether, diglycidyl resorsinol ether and the mixtures thereof.
  • a light curable composition according to the present invention may be prepared by any means of mixing all ingredients together to achieve a homogenous mixture.
  • the present invention also relates to a cured product of a composition according to the present invention.
  • a light curable composition according to the present invention can be cured for example by using high pressure mercury lamp for 60 seconds at 100 mW/cm 2 .
  • a light curable composition according to the present invention can be used as an adhesive or a sealant.
  • a light curable composition according to the present invention is particularly suitable for transparent substrates such as a glass and transparent plastics.
  • composition according to the present invention is suitable for use in optical modules such as integrated optic spectrum analyser (IOSA) for various laser detectors, infrared detectors and other telecommunication devices.
  • optical modules such as integrated optic spectrum analyser (IOSA) for various laser detectors, infrared detectors and other telecommunication devices.
  • IOSA integrated optic spectrum analyser
  • compositions of the examples were prepared by mixing all ingredients together to form a homogenous mixture.
  • UV light curability was confirmed by fixture by using high pressure mercury lamp for 60 seconds at 100 mW/cm 2 . All samples showed good UV light curability.
  • Adhesion strength of a glass substrate was measured after autoclave testing conditions. Two different kind of autoclave conditions were used; i) at 105°C in 100%humidity with 0.5 atmosphere pressure for 96 hours; and ii) at 121°C in 100%humidity with 1 atmosphere pressure for 12 hours.
  • Adhesion strength is measured according to the test method ASTM D2095.

Abstract

Provided is a light curable composition comprising a) an epoxy resin component; b) epoxy silane oligomer having a general structure (1) or (2) or (3); and c) a cationic photoinitiator. The said composition provides good adhesion properties even under autoclave conditions.

Description

Light cure epoxy composition Technical Field
The present invention relates to a light curable composition comprising an epoxy resin component, multifunctional epoxy silane oligomer and a cationic photoinitiator. Compositions according to the present invention provide good adhesive properties even under autoclave testing conditions.
Technical Background
Traditionally, thermosetting-type epoxy resins are used as adhesives. Cationically photocurable epoxy resins have been developed for various applications. This kind of epoxy resin compositions are advantageous because they provide cured products having comparable physical properties to thermosetting based compositions. Meaning that they are less inhibited by oxygen than a radical UV curable composition. In addition, they exhibit a smaller shrinkage than a radical UV curable composition. Therefore, these kind of compositions have been used in various well-known applications such as sealing of a liquid crystal display, lamination of a digital video disk, and sealing of a device package.
For example, for the formation of a device with hollow packages, such as CMOS, a device is placed in plastic or ceramic packages, and then the upper part is sealed with a glass plate by UV curable type of adhesives. These adhesives have to have, in addition to the sealing and adhesive property with glass, excellent moisture resistance, water resistance, and storage stability in high and low temperatures.
Thermally curable epoxy resin compositions can be cured by cationic polymerization by the application of heat. Such compositions comprise an alicyclic epoxy resin and/or bisphenol type epoxy resin as an epoxy resin, a photo-cationic polymerization initiator and/or thermo-cationic polymerization initiator as a curing agent, and at least one organosilicon compound as an additive. In this kind of compositions the organosilicon compound produces a silanol group upon light irradiation and/or heating and/or hydrolysis.
Prior art also discloses a cationically curable epoxy resin composition comprising: a) an epoxy resin component； b) a cationic photo-initiator； c) a cationic thermal-initiator； and d) a filler selected from the group consisting of oxides, hydroxides and carbonates containing a Group II element in the long periodic table. This kind of cationically curable epoxy resin compositions are especially useful as an adhesive when at least one of two materials to be attached is a glass.
Generally, a light curable cationic epoxy composition has no oxygen inhibition issue and the composition has very low cure shrinkage. Therefore, this kind of compositions have been used as light cure adhesives or sealants in optical applications. Compared to light curable free radical acrylate composition, light curable cationic epoxy composition has higher reliability performance even at high temperature and high humidity conditions. However, these light curable cationic epoxy compositions cannot withstand higher reliability requirements, i.e. autoclave conditions (higher than 100 ℃ with pressure applied) .
Therefore, there is still a need for a cationic epoxy composition, which cures well and the cured composition can provide a strong performance at autoclave humidity and temperature conditions.
Summary of the invention
The present invention relates to a light curable composition comprising a) an epoxy resin component； b) an epoxy silane oligomer having a general structure (1) :
Figure PCTCN2017079452-appb-000001
wherein n is an integer from 1 to 500； R1 is selected from the group consisting of C1-C10 alkyl group and aromatic group； R2 and R3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group；
； or a general structure (2) :
Figure PCTCN2017079452-appb-000002
wherein m is integer from 3 to 500； R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen； 
Figure PCTCN2017079452-appb-000003
and -Si (OR7) 3, wherein R7 is selected from the group consisting of hydrogen, methyl and ethyl；
or a general structure (3) :
Figure PCTCN2017079452-appb-000004
wherein o is integer from 3 to 500, R8, R9 and R10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group； and
c) a cationic photoinitiator.
The present invention also relates to a cured product of a composition according to the present invention.
The present invention further encompasses use of a composition according to the present invention as an adhesive or a sealant.
Detailed description of the invention
In the following passages the present invention is described in more detail. Each aspect so described may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.
In the context of the present invention, the terms used are to be construed in accordance with the following definitions, unless a context dictates otherwise.
As used herein, the singular forms “a” , “an” and “the” include both singular and plural referents unless the context clearly dictates otherwise.
The terms “comprising” , “comprises” and “comprised of” as used herein are synonymous with “including” , “includes” or “containing” , “contains” , and are inclusive or open-ended and do not exclude additional, non-recited members, elements or method steps.
The recitation of numerical end points includes all numbers and fractions subsumed within the respective ranges, as well as the recited end points.
All percentages, parts, proportions and then like mentioned herein are based on weight unless otherwise indicated.
When an amount, a concentration or other values or parameters is/are expressed in form of a range, a preferable range, or a preferable upper limit value and a preferable lower limit  value, it should be understood as that any ranges obtained by combining any upper limit or preferable value with any lower limit or preferable value are specifically disclosed, without considering whether the obtained ranges are clearly mentioned in the context.
All references cited in the present specification are hereby incorporated by reference in their entirety.
Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of the ordinary skill in the art to which this invention belongs to. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.
The present invention provides a light curable composition comprising a) an epoxy resin component； b) an epoxy silane oligomer having a general structure (1) :
Figure PCTCN2017079452-appb-000005
wherein n is an integer from 1 to 500；
R1 is selected from the group consisting of C1-C10 alkyl group and aromatic group；
R2 and R3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group；
or a general structure (2) :
Figure PCTCN2017079452-appb-000006
wherein m is integer from 3 to 500； R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen； 
Figure PCTCN2017079452-appb-000007
and -Si (OR7) 3, wherein R7 is selected from the group consisting of hydrogen, methyl and ethyl；
or a general structure (3) :
Figure PCTCN2017079452-appb-000008
wherein o is integer from 3 to 500, R8, R9 and R10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group； and
c) a cationic photoinitiator.
The light curable composition according to the present invention comprises an epoxy resin component. The suitable epoxy resin component may contain only one kind of epoxy resin or it may contain a mixture of two or more different kind of epoxy resins.
The epoxy resin component according to the present invention comprises preferably an aromatic-ring containing epoxy resin having at least one epoxy group in one molecule.
The suitable aromatic-ring containing epoxy resin having at least one epoxy group in one molecule for use in the present invention is selected from the group consisting of bisphenol-Aepoxy resins, bisphenol-F epoxy resins and bisphenol-Sepoxy resins, phenol novolac epoxy resins, cresol novolac epoxy resins, biphenyl epoxy resins and mixtures thereof.
Aromatic-ring containing epoxy resins having at least one epoxy group in one molecule are preferred because they provide better thermal and humidity resistance (they have relatively high Tg values and provides relatively low absorbance during PCT testing (pressure cooker test) ) .
Suitable commercially available epoxy resins for use in the present invention include, but are not limited to D. E. R. 331 and D. E. R. 383 from Olin Corporation.
A composition according to the present invention contains an epoxy resin component from 20 to 98％by weight by of total weight of the composition, preferably from 40 to 97％, more preferably from 65 to 95％and even more preferably from 75％to 90％.
Preferred range from 75％to 90％is desired because it provides ideal physical properties for the composition. On the other hand, if the quantity of an epoxy resin component is below 20％, the adhesion properties of the composition are poor, whereas the quantity greater than 98％leads to the decrease of the other desired features of the composition and in some cases this may lead to poor overall performance.
The main component of the epoxy resin component is an aromatic-ring containing epoxy resin, however, in some embodiments, the epoxy resin component may also comprise an alicyclic epoxy resin.
The use of the alicyclic epoxy resin in combination with aromatic-ring containing epoxy resin having at least one epoxy group in one molecule is found to increase the curing rate of the epoxy resin component according to the present invention. Furthermore, this combination is effective to cure within a short period of UV radiation. While it is known in that the use of alicyclic epoxy resin increases curing rate of UV cationic system, it also deteriorates the adhesive properties of the composition. On the contrary, the use of the epoxy resin component as defined herewith increases the curing rate while maintaining good adhesive properties.
Suitable alicyclic epoxy resin for use in the present invention is selected from the group consisting of
Figure PCTCN2017079452-appb-000009
and mixtures thereof.
A composition according to the present invention may comprise an alicyclic epoxy resin from 2 to 50％by weight of the total weight of the composition, preferably from 4 to 45％and more preferably from 5 to 40 ％.
It has been found that the range from 5 to 40％is preferred because it has positive impact to the cure speed without adversary affecting other properties. On the other hand, when the quantity of the alicyclic epoxy resin is below 2％, the component does not have positive effect on the cure speed, whereas quantity greater than 50％leads poor reliability performance at autoclave testing conditions.
Suitable commercially available alicyclic epoxy resin for use in the present invention include, but are not limited to Celloxide 2021 P and Celloxide 2018 from Daicel Corporation； Syna Epoxy 21 and Syna Epoxy 28 from Synasia Inc. .
The epoxy resin component according to the present invention may further comprise hydrogenated bisphenol type epoxy resins and dicyclopentadiene type epoxy resins. Hydrogenated bisphenol epoxy resins are compounds obtainable by hydrogenating benzene-rings in bisphenol epoxy resins such as bisphenol-Aepoxy resins, bisphenol-F epoxy resins, bisphenol-Sepoxy resins and the like. The use of these kind of epoxy resins as part of the epoxy resin component are found to increase the curing rate of the epoxy resin component remarkably and be effective to cure it with short period of UV radiation.
A composition according to the present invention comprises an epoxy silane oligomer. The epoxy silane oligomer used in the present invention is a multifunctional epoxy silane oligomer. By the term “multifunctional epoxy silane oligomer” is meant herein an oligomer, which has more than one silane group and more than one epoxy group in a molecule.
A multifunctional epoxy silane oligomer is used in the composition according to the present invention in order to improve the adhesion properties especially to inorganic substrates.
Suitable epoxy silane oligomer for use in the present invention has a general structure (1) :
Figure PCTCN2017079452-appb-000010
wherein n is an integer from 1 to 500, preferably from 1 to 300 and more preferably from 1 to 200；
R1 is selected from the group consisting of C1-C10 alkyl group and aromatic group； preferably R1 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, and more preferably R1 is propyl group；
R2 and R3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group；
preferably R2 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, and more preferably R2 is methyl group；
preferably R3 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, more preferably R3 is methyl group；
or a general structure (2) :
Figure PCTCN2017079452-appb-000011
wherein m is integer from 3 to 500, preferably from 3 to 300, and more preferably from 3 to 200； R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen； 
Figure PCTCN2017079452-appb-000012
and -Si (OR7) 3, wherein R7 is selected from the group consisting of hydrogen, methyl and ethyl；
preferably R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen； 
Figure PCTCN2017079452-appb-000013
and -Si (OR7) 3, wherein R7 is selected from the group consisting of hydrogen, methyl and ethyl, preferably R7 is methyl or ethyl, and wherein functional group equivalent of –Si (OR7) 3 to
Figure PCTCN2017079452-appb-000014
is 1 to 3；
or a general structure (3) :
Figure PCTCN2017079452-appb-000015
wherein o is integer from 3 to 500, preferably from 3 to 300, more preferably from 3 to 200；
R8, R9 and R10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group；
preferably R8 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, more preferably R8 is methyl group；
preferably R9 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, more preferably R9 is methyl group； and
preferably R10 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably, more preferably R10 is methyl group.
Preferred epoxy silane oligomers having preferred substituent groups are desired, because these epoxy silane oligomers provide in combination with the other ingredients, improved adhesive properties under autoclave testing conditions, and therefore, indicate a long time  reliability performance. Improved adhesive properties are especially seen when performance of a composition according to the present invention comprising a multifunctional epoxy silane oligomer is compared to performance of a composition comprising a monofunctional epoxy silane oligomer. This is exemplified in the examples.
In one preferred embodiment, epoxy silane oligomer has a structure (1) :
Figure PCTCN2017079452-appb-000016
wherein n is an integer from 1 to 200； R1 propyl group； R2 is methyl group； and R3 is methyl group.
In another preferred embodiment, epoxy silane oligomer has a structure (2) :
Figure PCTCN2017079452-appb-000017
wherein m is integer 3 to 200； R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen； 
Figure PCTCN2017079452-appb-000018
and -Si (OR7) 3, wherein R7 is methyl or ethyl, and wherein functional group equivalent of –Si (OR7) 3 to
Figure PCTCN2017079452-appb-000019
is 1 to 3.
Yet in another preferred embodiment, epoxy silane oligomer has a structure (3) :
Figure PCTCN2017079452-appb-000020
wherein o is integer from 3 to 200, R8 is methyl group； R9 is methyl group； and R10 is methyl group.
Suitable commercially available epoxy silane oligomers for use in the present invention include, but are not limited to CoatOsil MP200 from Momentive Performance Materials Incorporation； X-12-981S and KR-516 from Shin-Etsu Chemical Co., Ltd. .
A composition according to the present invention comprises epoxy silane oligomer from 0.1 to 10％by weight of the total weight of the composition, preferably from 0.3 to 9％, more preferably from 1.0 to 8.5％and even more preferably from 3 to 7％.
Range from 3 to 7％is preferred because this quantity provides ideal adhesion performance on inorganic substrates. On the other hand if the quantity of an epoxy silane oligomer is less than 0.1％, it has no effect to the physical properties of the composition, whereas quantity greater than 10％leads to poor adhesion performance.
The composition according to the present invention comprises a cationic photo-initiator. The suitable cationic photo-initiator for use in the present invention is a salt represented by formula A+B-which produces cationic active species by irritation of light.
The cation A+ is selected from the group consisting of aromatic iodonium ions and aromatic sulfonium ions. The anion B-is selected from the group consisting of SbF6 -, PF6 -, AsF6 -and B (Aryl) 4 -, B (C6F5) 4 -, B (C6F4OCF3) 4 -and B (C6F4CF3) 4 -.
The suitable aromatic iodonium ion for use in the present invention has the formula (9) :
Figure PCTCN2017079452-appb-000021
wherein groups Ar1 and Ar2 are same or different and independently to each other aromatic groups, phenyl groups, phenyl groups having substituent group.
Examples of preferred aromatic iodonium ion based cationic photoinitiators for use in the present invention are
Figure PCTCN2017079452-appb-000022
The suitable aromatic sulfonium ion for use in the present invention has the formula (16) :
Figure PCTCN2017079452-appb-000023
wherein groups Ar3, Ar4 and Ar5 are same or different and independently to each other aryl groups, phenyl groups, phenyl groups having substituent group.
Examples of preferred aromatic sulfonium ion based cationic photoinitiators for use in the present invention are
Figure PCTCN2017079452-appb-000024
Preferred cationic photoinitiator is selected from the group consisting of triarylsulfonium hexafluoroantimonate salt (17) and a mixture of compound (18) and compound (19) . These preferred cationic photoinitiators provide best performance.
Suitable commercially available cationic photoinitiator for use in the present invention include, but is not limited to CPI 6976 from Aceto Corporation.
A composition according to the present invention comprises a cationic photoinitiator from 0.1 to 10％by weight of the total weight of the composition, preferably from 0.3 to 9％, more preferably from 1.0 to 8.5％and even more preferably from 2 to 5％.
If the quantity of a cationic photoinitiator is below 0.1％the cure speed is not fast enough, whereas the quantity greater than 10％leads initiator contaminants in the composition.
A composition according to the present invention may further comprise an epoxy resin diluent. The epoxy resin diluent is used to adjust the viscosity of the composition.
Suitable epoxy resin diluent for use in the present invention is selected from the group consisting of cyclohexanedimethanol diglycidyl ether, butyl glycidyl ether, 2-ethylhexyl glycidyl ether, 4-tert-butylphenol glycidyl ether, glycidyl methacrylate and tertiary carboxylic acid glycidyl esters, styrene oxide, phenyl glycidyl ether, cresyl glycidyl ether, p-s-butylphenyl glycidyl ether, nonylphenyl glycidyl ether, tetrahydrofurfuryl alcohol glycidyl ether and mixtures thereof, preferably said epoxy resin diluent is 4-tert-butylphenol glycidyl ether.
4-tert-butylphenol glycidyl ether is preferred epoxy resin diluent because it provides a good thermal resistance while maintaining good dilution effect.
Suitable commercially available epoxy resin diluent for use in the present invention include, but are not limited to ED-509E and ED-509S from Adeka Corporation； DY-P from Huntsuman International LLC； and Erisys GE11 from CVC Thermoset Specialties.
A composition according to the present invention comprise from 1 to 20％by weight of total weight of the composition of an epoxy resin diluent, preferably from 5 to 15％and more preferably from 7 to 12％.
If the quantity of the epoxy resin diluent is lower than 1％it has no diluting effect, whereas the quantity greater than 20％would lead too low viscosity.
The composition according to the present invention may further contain an aromatic monoglycidyl ether and/or an aromatic biglycidyl ether such as cresyl glycidyl ether, nonyl phenyl glycidyl ether and phenyl glycidyl ether, diglycidyl resorsinol ether and the mixtures thereof.
A light curable composition according to the present invention may be prepared by any means of mixing all ingredients together to achieve a homogenous mixture.
The present invention also relates to a cured product of a composition according to the present invention. A light curable composition according to the present invention can be cured for example by using high pressure mercury lamp for 60 seconds at 100 mW/cm2.
A light curable composition according to the present invention can be used as an adhesive or a sealant.
A light curable composition according to the present invention is particularly suitable for transparent substrates such as a glass and transparent plastics.
Particularly, the composition according to the present invention is suitable for use in optical modules such as integrated optic spectrum analyser (IOSA) for various laser detectors, infrared detectors and other telecommunication devices.
Examples
The compositions of the examples were prepared by mixing all ingredients together to form a homogenous mixture.
UV light curability was confirmed by fixture by using high pressure mercury lamp for 60 seconds at 100 mW/cm2. All samples showed good UV light curability.
Adhesion strength of a glass substrate was measured after autoclave testing conditions. Two different kind of autoclave conditions were used； i) at 105℃ in 100％humidity with 0.5 atmosphere pressure for 96 hours； and ii) at 121℃ in 100％humidity with 1 atmosphere pressure for 12 hours.
Adhesion strength is measured according to the test method ASTM D2095.
Glass substrates adhered with the compositions according to the present invention and remained well. The adhesion strength was also good after autoclave testing conditions. Whereas glass substrates adhered with comparative samples delaminated. The adhesion strength decreased to zero after autoclave testing conditions (both conditions i and ii) .
Table 1
Figure PCTCN2017079452-appb-000025
1Bisphenol A epoxy resin (EEW: 190) , supplied by Olin Corporation.
2Bisphenol A epoxy resin (EEW: 180) , supplied by Olin Corporation.
3Hydrogenated bisphenol A epoxy resin, supplied by Mitsubishi Chemical Corporation.
4Multi-functional epoxy silane oligomer, supplied by Momentive Performance Materials Incorporation.
5Multifunctional epoxy silane oligomer, supplied by Shin-Etsu Chemical Co., Ltd.
6Cationic photo-initiator, supplied by Aceto Corporation.
7Measured by HAAKE RheoStress 3000 viscometer
8Cured with high pressure mercury lamp @100mW/cm2 for 60 seconds, slide glass used as substrate.

Claims (13)

  1. A light curable composition comprising
    a) an epoxy resin component；
    b) an epoxy silane oligomer having a general structure (1) :
    Figure PCTCN2017079452-appb-100001
    wherein n is an integer from 1 to 500；
    R1 is selected from the group consisting of C1-C10 alkyl group and aromatic group；
    R2 and R3 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group；
    or a general structure (2) :
    Figure PCTCN2017079452-appb-100002
    wherein m is integer from 3 to 500； R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen；
    Figure PCTCN2017079452-appb-100003
    and -Si (OR7) 3, wherein R7 is selected from the group consisting of hydrogen, methyl and ethyl；
    or a general structure (3) :
    Figure PCTCN2017079452-appb-100004
    wherein o is integer from 3 to 500, R8, R9 and R10 are same or different and independently selected from the group consisting of hydrogen, C1-C10 alkyl group and aromatic group； and
    c) a cationic photoinitiator.
  2. A composition according to claim 1, wherein said epoxy resin component is aromatic-ring containing epoxy resin selected from the group consisting of bisphenol-A epoxy resins, bisphenol-F epoxy resins and bisphenol-S epoxy resins, phenol novolac epoxy resins, cresol novolac epoxy resins, biphenyl epoxy resins and mixtures thereof.
  3. A composition according to claim 1 or 2, wherein said epoxy resin component is present from 20 to 98％by weight by of total weight of the composition, preferably from 40 to 97％, more preferably from 65 to 95％and even more preferably from 75％to 90％.
  4. A composition according to any of claims 1 to 3, wherein said epoxy resin component may further comprise an alicyclic epoxy resin selected from the group consisting of
    Figure PCTCN2017079452-appb-100005
    and mixtures thereof.
  5. A composition according to claim 4, wherein said alicyclic epoxy resin is present from 2 to 50％by weight of the total weight of the composition, preferably from 4 to 45％and more preferably from 5 to 40 ％.
  6. A composition according to any of claims 1 to 5, wherein said cationic photoinitiator is a salt represented by A+B- which produces cationic active species by irritation of light, and wherein the cation A+ is selected from the group consisting of aromatic iodonium ions and aromatic sulfonium ions, and wherein the anion B- is selected from the group consisting of SbF- 6, PF- 6, AsF- 6 and B (Aryl) - 4, B (C6F5) 4 -, B (C6F4OCF3) 4 - and B (C6F4CF3) 4 -.
  7. A composition according to any of claims 1 to 6, wherein said cationic photoinitiator is present from 0.1 to 10％by weight of the total weight of the composition, preferably from 0.3 to 9％, more preferably from 1.0 to 8.5％and even more preferably from 2 to 5％.
  8. A composition according to any of claims 1 to 7, wherein said epoxy silane oligomer has a general structure (1) :
    Figure PCTCN2017079452-appb-100006
    wherein n is an integer from 1 to 300, preferably from 1 to 200；
    R1 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably R1 is propyl group；
    R2 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably R2 is methyl group；
    R3 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably R3 is methyl group；
    or a general structure (2) :
    Figure PCTCN2017079452-appb-100007
    wherein m is integer from 3 to 300, preferably from 3 to 200； R4, R5 and R6 are same or different and independently selected from the group consisting of hydrogen；
    Figure PCTCN2017079452-appb-100008
    and -Si (OR7) 3, wherein R7 is selected from the group consisting of hydrogen, methyl and ethyl, preferably R7 is methyl or ethyl, and
    wherein functional group equivalent of –Si (OR7) 3 to
    Figure PCTCN2017079452-appb-100009
    is 1 to 3；
    or a general structure (3) :
    Figure PCTCN2017079452-appb-100010
    wherein o is integer from 3 to 300, preferably from 3 to 200, R7 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably R7 is methyl group；
    R8 is selected from the group consisting of hydrogen, methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably R8 is methyl group； and
    R9 is selected from the group consisting of methyl group, ethyl group, propyl group, butyl group, aromatic group, preferably R7 is methyl group.
  9. A composition according to any of claims 1 to 7, wherein said epoxy silane oligomer is present from 0.1 to 10％by weight of the total weight of the composition, preferably from 0.3 to 9％, more preferably from 1.0 to 8.5％and even more preferably from 3 to 7％.
  10. A composition according to any of claims 1 to 9, composition may further comprise an epoxy resin diluent selected from the group consisting of cyclohexanedimethanol  diglycidyl ether, butyl glycidyl ether, 2-ethylhexyl glycidyl ether, 4-tert-butylphenol glycidyl ether, glycidyl methacrylate and tertiary carboxylic acid glycidyl esters, styrene oxide, phenyl glycidyl ether, cresyl glycidyl ether, p-s-butylphenyl glycidyl ether, nonylphenyl glycidyl ether, tetrahydrofurfuryl alcohol glycidyl ether and mixtures thereof, preferably said epoxy resin diluent is 4-tert-butylphenol glycidyl ether.
  11. A composition according to claim 10 comprise from 1 to 20％by weight of total weight of the composition of an epoxy resin diluent, preferably from 5 to 15％and more preferably from 7 to 12％.
  12. A cured product of a composition according to any of claims 1 to 11.
  13. Use of composition according any of claims 1 to 11 as an adhesive or a sealant.
PCT/CN2017/079452 2017-04-05 2017-04-05 Light cure epoxy composition WO2018184151A1 (en)

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