WO2015005464A1 - 光取出し用樹脂組成物 - Google Patents
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- WO2015005464A1 WO2015005464A1 PCT/JP2014/068533 JP2014068533W WO2015005464A1 WO 2015005464 A1 WO2015005464 A1 WO 2015005464A1 JP 2014068533 W JP2014068533 W JP 2014068533W WO 2015005464 A1 WO2015005464 A1 WO 2015005464A1
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- resin composition
- resin
- light extraction
- light
- composition according
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/005—Modified block copolymers
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/85—Arrangements for extracting light from the devices
- H10K50/854—Arrangements for extracting light from the devices comprising scattering means
Definitions
- This invention relates to the resin composition for light extraction used in order to improve the luminous efficiency of light emitting devices, such as an organic EL device.
- the light emitting layer of an organic EL (Electroluminescence) device generally has a higher refractive index of light than glass or air used for a substrate (transparent substrate), so there is a lot of light that is reflected and confined inside the device. Only about 20% of the total light emission can be taken out (outside the device). For this reason, in order to raise the light extraction efficiency, a technology such as providing a concavo-convex structure on a transparent substrate (see, for example, Patent Document 1) or providing a light scattering structure in a device (for example, Patent Document 2). It has been known. However, the light extraction efficiency has not reached a satisfactory level, and further improvement is expected. Note that the problem that light cannot be efficiently extracted out of the device is a potential problem not only in organic EL devices but also in other light emitting devices.
- the present invention has been made in view of the above circumstances, and the problem to be solved is a resin composition for light extraction that can sufficiently increase the light extraction efficiency in a light-emitting device, in particular, a light-emitting device.
- An object of the present invention is to provide a light extraction resin composition capable of forming a light extraction layer capable of taking out light with high efficiency by being in close contact with a transparent substrate.
- a light extraction resin composition comprising (A) a styrene-isobutylene-modified resin, (B) a tackifier resin, and (C) a filler.
- the (C) filler is a filler having a refractive index 0.2 or more larger than the refractive index of the (A) styrene-isobutylene-modified resin.
- the filler is at least one selected from titanium oxide, aluminum oxide, zirconium oxide, cerium oxide, and barium titanate.
- the functional group is selected from the group consisting of an acid anhydride group, epoxy group, carboxyl group, amino group, hydroxyl group, isocyanate group, oxazoline group, oxetane group, cyanate group, phenol group, hydrazide group and amide group.
- [15] The resin composition according to any one of [1] to [14], which is for a light extraction layer laminated on a transparent substrate of a light emitting device.
- a light extraction film comprising the resin composition according to any one of [1] to [13].
- the light extraction film according to the above [17] or [18] which has a refractive index of 1.45 to 1.60.
- a light extraction film, wherein the layer of the resin composition according to any one of [1] to [13] is formed on a transparent film.
- the resin composition for light extraction of the present invention it is possible to form a light extraction layer having high light extraction efficiency and in close contact with a transparent substrate with high adhesive force.
- the light extraction layer formed by the resin composition of the present invention becomes a light extraction layer that adheres to the transparent substrate with high adhesive force, and not only sufficiently enhances the light extraction efficiency of the light emitting device (particularly the organic EL device), The light distribution characteristics and the viewing angle hue difference can also be greatly improved. Therefore, according to the present invention, it is possible to realize a light emitting device (particularly, an organic EL device) that operates stably with high light emission efficiency over a long period of time and emits light with no sense of incompatibility such as natural light.
- the resin composition for light extraction of the present invention (hereinafter, also simply referred to as “the resin composition of the present invention”)
- the resin composition of the present invention is used to increase the light extraction efficiency in a light emitting device such as an organic EL device, and is usually formed as a light extraction layer laminated on a transparent substrate of the light emitting device.
- a varnish obtained by dissolving or dispersing the resin composition of the present invention in a solvent is coated on a transparent film and dried, whereby a resin composition layer for a light extraction layer by the resin composition of the present invention on one side of the transparent film.
- a light extraction film in which is formed can be obtained.
- the “refractive index” as used in the present invention is a refractive index of light having a wavelength of 589 nm at 25 ° C., and is a value based on the following measurement method.
- Refractive index of resin raw material, resin composition and film The refractive index of a sample can be determined by measuring the critical angle at the interface between a prism whose refractive index is known and the sample adhering thereto by the prism coupling method. .
- a 2010M prism coupler manufactured by Metricon Corporation
- Refractive index of filler Measures the 589-nm parallel-line transmittance of a mixture obtained by mixing several kinds of immersion liquids and fillers whose refractive indexes are known in advance at a predetermined mixing ratio by an immersion method.
- the refractive index of the immersion liquid that maximizes the number is taken as the refractive index of the filler.
- the mixing ratio of the mixture can be set as appropriate so that the maximum value of the measured values can be easily identified.
- the immersion liquid a generally available immersion liquid can be used. For example, a mixture of 1-iodonaphthalene, diiodomethane, etc., whose refractive index is measured in advance by applying the prism coupling method described above. Alternatively, a standard immersion liquid can be used.
- a generally available spectrophotometer can be used.
- MCPD-7700 manufactured by Otsuka Electronics Co., Ltd.
- the refractive index of the filler exceeds the range measurable by the immersion method, it can be measured by applying the prism coupling method to a bulk body made of the main material of the filler.
- the styrene-isobutylene-modified resin (hereinafter also referred to as “component (A)”) in the resin composition of the present invention is a copolymer containing a styrene skeleton and an isobutylene skeleton, and any functional group may be used. It is not limited.
- the form of the copolymer is not particularly limited, and examples thereof include a random copolymer, a block copolymer, and a graft copolymer.
- Such a styrene-isobutylene-modified resin is preferably solid at room temperature (25 ° C.).
- a block copolymer containing a polystyrene block (polystyrene skeleton) and a polyisobutylene block (polyisobutylene skeleton) having a functional group that is, a polystyrene block (polystyrene skeleton) and And a modified block copolymer having a functional group in at least one polymer block of a block copolymer containing a polyisobutylene block (polyisobutylene skeleton).
- the form of the block copolymer in such a modified block copolymer is not particularly limited, but a polystyrene block (polystyrene skeleton) —a diblock copolymer comprising a polyisobutylene block (polyisobutylene skeleton), a polystyrene block (polystyrene skeleton) — Examples thereof include a triblock copolymer comprising a polyisobutylene block (polyisobutylene skeleton) -polystyrene block (polystyrene skeleton), and preferably a polystyrene block (polystyrene skeleton) -polyisobutylene block (polyisobutylene skeleton) -polystyrene block.
- the polyisobutylene skeleton may be a homopolymer of isobutylene or a copolymer obtained by copolymerizing an appropriate amount of an olefin compound such as 1-butene and 2-butene with isobutylene.
- the polystyrene skeleton may be a homopolymer of styrene or a copolymer obtained by copolymerizing at least one appropriate amount selected from p-methylstyrene, ⁇ -methylstyrene, and indene.
- the proportion of the polyisobutylene skeleton is 40% by mass with respect to the entire component (A) (that is, when the modified block copolymer is 100% by mass) from the viewpoint of the adhesiveness of the resin composition to the transparent substrate.
- the above is preferable, 50 mass% or more is more preferable, and 60 mass% or more is still more preferable. Moreover, 98 mass% or less is preferable, 95 mass% or less is more preferable, and 90 mass% or less is still more preferable.
- Examples of functional groups include, but are not limited to, acid anhydride groups, epoxy groups, carboxy groups, amino groups, hydroxy groups, isocyanate groups, oxazoline groups, oxetane groups, cyanate groups, phenol groups, hydrazide groups, amide groups, and the like. be able to.
- the functional group may be one type or two or more types. From the viewpoint of the adhesiveness of the resin composition to the transparent substrate, an acid anhydride group and an epoxy group are more preferable. These functional groups may be one type or two or more types.
- the functional group concentration in the styrene-isobutylene-modified resin is preferably 0.05 to 10 mmol / g.
- the acid anhydride group concentration is preferably 0.05 to 10 mmol / g, more preferably 0.2 to 5 mmol / g.
- the acid anhydride group concentration referred to here is obtained from the value of the acid value defined as the number of mg of potassium hydroxide required to neutralize the acid present in 1 g of the resin according to the description of JISK 2501.
- the epoxy group concentration is preferably 0.05 to 10 mmol / g, more preferably 0.2 to 5 mmol / g.
- the epoxy group concentration is determined from the epoxy equivalent obtained based on JISK 7236-1995.
- the styrene-isobutylene-modified resin is, for example, a styrene-isobutylene resin (for example, a block copolymer comprising a polystyrene block (polystyrene skeleton) and a polyisobutylene block (polyisobutylene skeleton)) under radical reaction conditions. It can be obtained by graft modification with an unsaturated compound containing a functional group.
- a modified resin having an acid anhydride group for example, maleic anhydride-modified styrene-isobutylene-styrene block copolymer
- a modified resin having an epoxy group for example, glycidyl methacrylate-modified styrene-isobutylene-styrene block copolymer
- the refractive index of the styrene-isobutylene modified resin of the present invention is preferably 1.45 to 1.60, more preferably 1.47 to 1.57.
- the light extraction layer of the light emitting device needs to be equivalent to the refractive index of the transparent substrate (usually 1.48 to 1.55).
- the refractive index of the resin composition of the present invention can be easily adjusted to a refractive index equivalent to the refractive index of the transparent substrate.
- the number average molecular weight of the component (A) is not particularly limited, but is preferably 500,000 or less, more preferably 300,000 or less, and more preferably 150,000 or less, from the viewpoints of film forming properties of the resin composition, compatibility with other components, and the like. preferable. On the other hand, 10,000 or more are preferable and 30000 or more are more preferable from the viewpoints of preventing repelling during coating of the varnish of the resin composition and improving the mechanical strength of the resin composition.
- the number average molecular weight in this invention is measured by the gel permeation chromatography (GPC) method (polystyrene conversion).
- the number average molecular weight determined by the GPC method is LC-9A / RID-6A manufactured by Shimadzu Corporation as a measuring device, Shodex K-800P / K-804L / K-804L manufactured by Showa Denko KK as a column, and mobile phase. It can be calculated using a calibration curve of standard polystyrene by measuring at a column temperature of 40 ° C. using toluene or the like.
- a component can be used 1 type or in combination of 2 or more types.
- Preferred embodiments include, for example, a modified resin having an acid anhydride group (for example, maleic anhydride-modified styrene-isobutylene-styrene block copolymer) and a modified resin having an epoxy group (for example, glycidyl methacrylate-modified styrene-isobutylene-styrene).
- a modified resin having an acid anhydride group for example, maleic anhydride-modified styrene-isobutylene-styrene block copolymer
- an epoxy group for example, glycidyl methacrylate-modified styrene-isobutylene-styrene
- the compounding ratio of both (modified resin having an acid anhydride group: having an epoxy group)
- the modified resin is preferably in a mass ratio of 1: 0.3 to 1: 3, more preferably 1: 1 to 1: 1.6.
- a preferred specific example of the component (A) is a maleic anhydride-modified styrene-isobutylene-styrene block copolymer which is a modified block copolymer having an acid anhydride group (for example, T-YP926, manufactured by Seiko PMC). And glycidyl methacrylate-modified styrene-isobutylene-styrene block copolymer (for example, T-YP927 manufactured by Seiko PMC), which is a modified block copolymer having an epoxy group.
- (A) component can use 1 type (s) or 2 or more types.
- content of (A) component in the resin composition of this invention The film formability (coatability of the varnish of a resin composition) of a resin composition, a refractive index, the handleability in normal temperature, etc.
- the content of the component (A) is preferably 80% by mass or less, more preferably 75% by mass or less, and still more preferably 70% by mass or less based on the entire nonvolatile content in the resin composition.
- the content of the component (A) is preferably 35% by mass or more, and 40% by mass or more, based on the entire nonvolatile content in the resin composition. More preferred is 45% by mass or more.
- the (B) tackifier resin (hereinafter also abbreviated as “component (B)”) used in the present invention is also called a tackifier, and is a resin that is added to a plastic polymer to impart tackiness.
- the component (B) is not particularly limited, and is not limited to terpene resin, modified terpene resin (hydrogenated terpene resin, terpene phenol copolymer resin, aromatic modified terpene resin, etc.), coumarone resin, indene resin, petroleum resin ( Aliphatic petroleum resins, hydrogenated alicyclic petroleum resins, aromatic petroleum resins, aliphatic aromatic copolymer petroleum resins, alicyclic petroleum resins, dicyclopentadiene petroleum resins and their hydrides) Preferably used. Among these, from the viewpoints of adhesion, transparency, compatibility with the component (A), etc.
- terpene resin aromatic modified terpene resin, terpene phenol copolymer resin, hydrogenated alicyclic petroleum resin, aromatic Aromatic petroleum resins, aliphatic aromatic copolymer petroleum resins, alicyclic petroleum resins are more preferred, alicyclic petroleum resins are more preferred, alicyclic saturated hydrocarbon resins, alicyclic unsaturated hydrocarbons Resins are still more preferred, and cyclohexyl ring-containing saturated hydrocarbon resins are most preferred.
- Component (B) may be used alone or in combination of two or more.
- the softening point of the component (B) is from the viewpoint that the resin composition layer is softened at the time of heat lamination to the transparent substrate of the light extraction sheet, and is formed into a light extraction layer having sufficient heat resistance after the heat lamination. 50 to 200 ° C is preferable, 90 to 180 ° C is more preferable, 100 to 150 ° C is further preferable, and 120 to 145 ° C is still more preferable.
- the softening point is measured by the ring and ball method according to JIS K2207.
- Examples of commercially available products that can be used as the component (B) include YS resin PX, YS resin PXN (both manufactured by Yasuhara Chemical Co., Ltd.) and the like as terpene resins, and YS resin TO and TR series (any of aromatic modified terpene resins).
- YS resin PX YS resin PX
- YS resin PXN both manufactured by Yasuhara Chemical Co., Ltd.
- YS resin TO and TR series any of aromatic modified terpene resins.
- hydrogenated terpene resins include Clearon P, Clearon M, Clearon K series (all manufactured by Yasuhara Chemical Co., Ltd.)
- terpene phenol copolymer resins are YS Polystar 2000, Polystar U.
- the refractive index of the tackifying resin of the present invention is preferably 1.45 to 1.60, more preferably 1.47 to 1.57.
- the filler used in the present invention (hereinafter also abbreviated as “component (C)”) is an inorganic filler as long as the refractive index is 0.2 or more larger than the refractive index of the styrene-isobutylene-modified resin of component (A). Either a filler or an organic filler can be used.
- component (C) is an inorganic filler as long as the refractive index is 0.2 or more larger than the refractive index of the styrene-isobutylene-modified resin of component (A).
- a light extraction layer capable of obtaining a high light extraction effect can be formed.
- the refractive index of the filler is preferably 0.22 or more, and more preferably 0.25 or more, greater than the refractive index of the styrene-isobutylene modified resin.
- the upper limit of the difference in refractive index between the filler and the styrene-isobutylene-modified resin is not particularly limited, but is preferably 1.0 or less from the viewpoint of cost and the like.
- Preferred fillers include titanium oxide (refractive index: 2.4), aluminum oxide (refractive index: 1.76), zirconium oxide (refractive index: 2.2), cerium oxide (refractive index: 2.2), titanium. Examples thereof include barium acid (refractive index: 2.2), and particularly preferable fillers are titanium oxide and aluminum oxide. 1 type (s) or 2 or more types can be used for a filler.
- the particle shape of the filler is not particularly limited, and examples thereof include a spherical shape, a needle shape, a plate shape, and an indefinite shape. Further, the average particle diameter of the filler is not particularly limited, and can be appropriately selected from the viewpoints of light scattering properties, light extraction efficiency (front extraction efficiency) of the resin composition, and the like. Mainly from the viewpoint of light scattering properties, the average particle size of the filler is preferably 0.5 ⁇ m or more, and more preferably 1 ⁇ m or more. Further, from the viewpoint of mainly light extraction efficiency (front extraction efficiency), the average particle size of the filler is preferably 50 ⁇ m or less, and more preferably 15 ⁇ m or less.
- the average particle size of the filler approaches the thickness of the light extraction layer (resin composition layer)
- the adhesion of the light extraction layer (resin composition layer) tends to decrease, so the average particle size of the filler is One third or less of the thickness of the light extraction layer (resin composition layer) is preferable.
- the particle shape and average particle diameter of the filler in the present invention are physical properties in the light extraction layer (resin composition layer) and are based on transmission observation with an optical microscope.
- the average particle size is calculated by observing the light extraction layer (resin composition layer) with an optical microscope and measuring the particle size of 10 or more particles in the field of view.
- the blending amount of the filler in the resin composition is not particularly limited, and can be appropriately selected from the viewpoints of light scattering properties, light extraction efficiency (front extraction efficiency) of the resin composition, and the like.
- the blending amount of the filler is preferably 0.5% by mass or more, more preferably 1% by mass or more, and further preferably 2% by mass or more, based on the entire nonvolatile content of the resin composition.
- the filler content is preferably 50% by mass or less, more preferably 40% by mass or less, based on the entire nonvolatile content of the resin composition. More preferably, it is 30 mass% or less.
- the resin composition of the present invention may further contain a curing agent (hereinafter also abbreviated as “(D) component”).
- a curing agent (crosslinking agent) is contained suitably according to the functional group which (A) component has.
- the use of a curing agent (crosslinking agent) is suitable when the component (A) includes a styrene-isobutylene-modified resin having an epoxy group.
- examples of the curing agent include epoxy curing agents such as amine curing agents, guanidine curing agents, imidazole curing agents, phosphonium curing agents, and phenol curing agents.
- a component can use 1 type (s) or 2 or more types.
- the amine curing agent is not particularly limited, but is a quaternary ammonium salt such as tetramethylammonium bromide or tetrabutylammonium bromide; DBU (1,8-diazabicyclo [5.4.0] undecene-7), DBN ( 1,5-diazabicyclo [4.3.0] nonene-5), DBU-phenol salt, DBU-octylate, DBU-p-toluenesulfonate, DBU-formate, DBU-phenol novolac resin salt, etc.
- quaternary ammonium salt such as tetramethylammonium bromide or tetrabutylammonium bromide
- DBU 1,8-diazabicyclo [5.4.0] undecene-7
- DBN 1,5-diazabicyclo [4.3.0] nonene-5
- DBU-phenol salt DBU-octylate
- Diazabicyclo compounds such as benzyldimethylamine, 2- (dimethylaminomethyl) phenol, 2,4,6-tris (dimethylaminomethyl) phenol and their salts, aromatic dimethylurea, aliphatic dimethylurea, aromatic Dimethylurea compounds such as group dimethylurea; and the like. You may use these 1 type or in combination of 2 or more types.
- the guanidine curing agent is not particularly limited, but dicyandiamide, 1-methylguanidine, 1-ethylguanidine, 1-cyclohexylguanidine, 1-phenylguanidine, 1- (o-tolyl) guanidine, dimethylguanidine, diphenylguanidine, Trimethyl guanidine, tetramethyl guanidine, pentamethyl guanidine, 1,5,7-triazabicyclo [4.4.0] dec-5-ene, 7-methyl-1,5,7-triazabicyclo [4.4 .0] dec-5-ene, 1-methyl biguanide, 1-ethyl biguanide, 1-n-butyl biguanide, 1-n-octadecyl biguanide, 1,1-dimethyl biguanide, 1,1-diethyl biguanide, 1-cyclohexyl Biguanide, 1-allyl biguanide, 1-phenyl biguanide 1-(o-to
- the imidazole curing agent is not particularly limited, but 1H-imidazole, 2-methylimidazole, 2-phenyl-4-methyl-imidazole, 1-cyanoethyl-2-ethyl-4-methyl-imidazole, 2-phenyl-4 , 5-bis (hydroxymethyl) -imidazole, 1-benzyl-2-methylimidazole, 1-benzyl-2-phenylimidazole, 2-ethyl-4-methylimidazole, 2-phenyl-imidazole, 2-dodecyl-imidazole, Examples include 2-heptadecylimidazole and 1,2-dimethyl-imidazole. You may use these 1 type or in combination of 2 or more types.
- the phosphonium curing agent is not particularly limited, but is triphenylphosphine, phosphonium borate compound, tetraphenylphosphonium tetraphenylborate, n-butylphosphonium tetraphenylborate, tetrabutylphosphonium decanoate, (4-methylphenyl) triate.
- Examples thereof include phenylphosphonium thiocyanate, tetraphenylphosphonium thiocyanate, and butyltriphenylphosphonium thiocyanate. You may use these 1 type or in combination of 2 or more types.
- the type of phenolic curing agent is not particularly limited, but is MEH-7700, MEH-7810, MEH-7851 (Maywa Kasei), NHN, CBN, GPH (Nippon Kayaku), SN170, SN180, SN190. SN475, SN485, SN495, SN375, SN395 (manufactured by Tohto Kasei), TD2090 (manufactured by DIC), and the like.
- Specific examples of the triazine skeleton-containing phenolic curing agent include LA3018 (manufactured by DIC).
- Specific examples of the triazine skeleton-containing phenol novolak curing agent include LA7052, LA7054, LA1356 (manufactured by DIC) and the like. You may use these 1 type or in combination of 2 or more types.
- the resin composition of the present invention includes any substance such as a substance that absorbs light of a specific wavelength, a substance that adjusts light scattering properties, etc., in addition to the components (A) to (D), as long as the effects of the present invention are not impaired. Ingredients can be further blended.
- the resin composition of the present invention is prepared by mixing the blended components using a kneading roller, a rotating mixer, or the like, further adding a solvent or the like as necessary.
- the refractive index of the resin composition of the present invention is preferably 1.45 to 1.60, more preferably 1.47 to 1.57.
- the refractive index of a resin composition is a refractive index of solid content.
- ⁇ Light extraction layer> For example, a varnish prepared by dissolving or dispersing the resin composition of the present invention in a solvent is prepared, and the resin composition layer is formed by applying and drying the varnish on the transparent substrate of the light emitting device.
- the light extraction layer is a layer that adheres to the transparent substrate with a high adhesive force. There are no particular restrictions on the drying conditions, but 50 to 100 ° C. for 1 to 60 minutes is preferable.
- the resin composition layer may be further heated to obtain a cured product.
- organic solvents examples include ketones such as acetone, methyl ethyl ketone (hereinafter also abbreviated as “MEK”), cyclohexanone; and acetates such as ethyl acetate, butyl acetate, cellosolve acetate, propylene glycol monomethyl ether acetate, and carbitol acetate.
- ketones such as acetone, methyl ethyl ketone (hereinafter also abbreviated as “MEK”), cyclohexanone
- acetates such as ethyl acetate, butyl acetate, cellosolve acetate, propylene glycol monomethyl ether acetate, and carbitol acetate.
- Carbitols such as cellosolve and butyl carbitol
- aromatic hydrocarbons such as toluene and xylene
- dimethylformamide dimethylacetamide, N-methylpyrrolidone
- aromatic mixed solvents examples include “Swazole” (trade name, manufactured by Maruzen Petroleum Corporation) and “Ipsol” (trade name, manufactured by Idemitsu Kosan Co., Ltd.).
- the organic solvent may be used alone or in combination of two or more.
- the light extraction layer closely adhered to the transparent substrate with high adhesive force can also be formed by thermally laminating the light extraction film, which will be described in detail later, on the transparent substrate of the light emitting device.
- the thickness of the light extraction layer is preferably 1 to 60 ⁇ m, more preferably 5 to 40 ⁇ m, still more preferably 15 to 30 ⁇ m.
- the lower limit value can be appropriately determined from the viewpoint of adhesion, and the upper limit value can be appropriately determined from the viewpoint of front extraction efficiency.
- the total light transmittance of the light extraction layer is preferably 55 to 90%, more preferably 60 to 80%.
- the lower limit value can be determined as appropriate from the viewpoint of front extraction efficiency, and the upper limit value can be determined as appropriate from the viewpoint of light scattering properties.
- the refractive index of the light extraction layer is preferably 1.45 to 1.60, more preferably 1.47 to 1.57.
- the light extraction film of the present invention includes a single-layer film made of the resin composition of the present invention and a multilayer film in which a layer (light extraction layer) of the resin composition of the present invention is formed on a transparent film.
- the single-layer film is formed by molding the resin composition of the present invention into a film by a known film molding method, or a varnish obtained by dissolving or dispersing the resin composition of the present invention in a solvent (preferably a release treatment). Applied to the base material), dried, and peeled off the dried film.
- the multilayer film can be obtained by applying a varnish obtained by dissolving or dispersing the resin composition of the present invention in a solvent on a transparent film and drying it.
- the thickness of the light extraction film is preferably 1 to 60 ⁇ m, more preferably 5 to 40 ⁇ m, and still more preferably 15 to 30 ⁇ m.
- the lower limit value of the thickness of the light extraction film can be appropriately determined from the viewpoint of adhesion, and the upper limit value can be appropriately determined from the viewpoint of front extraction efficiency.
- the total light transmittance of the light extraction film is preferably 55 to 90%, more preferably 60 to 80%.
- the lower limit value of the total light transmittance can be determined as appropriate from the viewpoint of front extraction efficiency, and the upper limit value can be determined as appropriate from the viewpoint of light scattering properties.
- the refractive index of the light extraction film is preferably 1.45 to 1.60, more preferably 1.47 to 1.57.
- the thickness of the light extraction film, the total light transmittance and the refractive index means that when the light extraction film is a single layer film, the thickness of the single layer film and the total light transmittance In the case of a multilayer film, it means the thickness, the total light transmittance and the refractive index of the layer (light extraction layer) of the resin composition of the present invention.
- the light extraction film of the present invention is a multilayer film
- the light extraction film is heat-laminated to the transparent substrate with the resin composition layer side facing the transparent substrate, thereby being adhered to the transparent substrate with high adhesive force.
- a light extraction structure in which the light extraction layer is covered with a transparent film is formed.
- a transparent plastic film is usually used for the transparent film.
- transparent plastic films include polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polyethylene-2,6-naphthalate (PEN); polyamides such as nylon 6 and nylon 6,6; polyethylene (PE) Polyolefin such as polypropylene (PP); Polycarbonate (PC); Polyacryl such as polymethyl methacrylate (PMMA); ABS resin; AES resin; Polychlorinated biphenyl; Polyvinyl alcohol; Polyurethane, polyimide; Polytetrafluoroethylene (PTFE) And films of fluorine-based resins such as ethylenetetrafluoroethylene (ETFE).
- PET polyethylene terephthalate
- PBT polybutylene terephthalate
- PEN polyethylene-2,6-naphthalate
- PE polyolefin
- PP polypropylene
- PC Polycarbonate
- PMMA polymethyl methacrylate
- ABS resin
- the refractive index of the transparent plastic film is not particularly limited. This is because the light that has been totally reflected at the interface between the light extraction layer and the transparent plastic film is diffusely reflected at the interface between the transparent plastic film and the resin composition of the present invention, thereby exhibiting the light extraction effect from the transparent plastic film. Because. In order to exhibit a high light extraction effect, it is preferable to select one that is more preferably 1.6 or less, and even more preferably 1.5 or less.
- the thickness of the transparent film is not particularly limited, but is preferably about 5 to 500 ⁇ m and more preferably about 25 to 200 ⁇ m from the viewpoint of easy handling of the light extraction film and weather resistance.
- the transparent film can be subjected to a surface treatment in advance. For example, in addition to blast treatment, chemical treatment, degreasing, flame treatment, oxidation treatment, steam treatment, corona discharge treatment, ultraviolet irradiation treatment, plasma treatment, ion treatment, etc., release treatment may be performed.
- the light extraction film of the present invention is protected with a protective film until it is actually laminated to the transparent substrate of the light-emitting device in order to prevent adhesion or scratches of dust or the like on the surface of the resin composition layer of the light extraction film. It is preferable that a plastic film can be used as the protective film.
- the protective film may be subjected to a mold release treatment in addition to a mat treatment and a corona treatment.
- the light extraction structure including the resin composition layer (light extraction layer) of the present invention can also be formed by the following method. That is, the resin composition layer transfer film in which the resin composition layer (light extraction layer) is formed on one side of the support film (first film) is placed on the transparent substrate with the resin composition layer side facing the transparent substrate. After heat laminating, the film is peeled off, and the transparent film (second film) is heat laminated to the resin composition layer (resin composition layer transferred to the transparent substrate) remaining on the transparent substrate.
- a light extraction structure is formed in which the resin composition layer (light extraction layer) adhered to the substrate with high adhesive force is covered with a transparent film.
- any film including the above-mentioned transparent plastic film should be used for this film. Can do.
- the thickness of the film is preferably about 5 to 150 ⁇ m, more preferably about 25 to 50 ⁇ m, from the viewpoint of easy handling of the film, peelability, durability, and the like.
- the above-mentioned transparent plastic film is usually used as the second film which is a transparent film, and the thickness of the film is preferably about 5 to 500 ⁇ m from the viewpoint of functionality, weather resistance, etc. Preferably, it is about 25 to 200 ⁇ m.
- the first film and the second film can be subjected to surface treatment in advance.
- surface treatment for example, in addition to blast treatment, chemical treatment, degreasing, flame treatment, oxidation treatment, steam treatment, corona discharge treatment, ultraviolet irradiation treatment, plasma treatment, ion treatment, etc., release treatment may be performed.
- the light emitting device referred to in the present invention is a concept including an organic EL device, an inorganic EL device, an LED, a fluorescent tube, and the like, and typically, an illumination application such as an organic EL lighting device (panel module) or an LED lighting device. It is a light emitting device.
- the light-emitting device of the present invention includes those in which a light extraction layer made of the resin composition of the present invention is in close contact with a transparent substrate serving as a light-emitting surface of the device, and a light-extraction layer further laminated with a transparent film.
- the light extraction layer formed by the resin composition of the present invention not only improves the light extraction efficiency of the light emitting device, but also greatly improves the light distribution characteristics and the viewing angle hue difference.
- Example 1 A light extraction film was obtained by the method described below. Unless otherwise specified, the number of parts by mass (hereinafter abbreviated as “part”) of each component is a value converted in terms of solid content.
- This mixture was further mixed for 30 minutes using a high-speed dispersion mixer (Ajihomo mixer, rotation speed 3000 rpm). This was designated as the first agent.
- Maleic anhydride-modified styrene-isobutylene-styrene block copolymer (T-YP926, 40% swazole-1000 solution) 40 parts, cyclohexyl ring-containing saturated hydrocarbon resin (Arcon P125), cyclohexyl ring-containing saturated hydrocarbon resin 20 parts of (Alcon P140) was added and dissolved by heating at 80 ° C. for 2 hours until uniform using a rotating mixer (planetary mixer, rotation speed 75 rpm). This was the second agent.
- the obtained varnish was coated on a PET film (E7004, manufactured by Toyobo Co., Ltd.) at a coating thickness of 100 ⁇ m with a hand coater, and heated in a 100 ° C. heat circulation oven for 30 minutes and in a 130 ° C. heat circulation oven for 60 minutes.
- the PET film was peeled off, and a glass plate (length 76 mm, width 26 mm, thickness 1.2 mm, micro slide glass) was further laminated on the exposed resin composition layer (light extraction layer) under the same conditions as above. .
- the obtained laminate was held for 24 hours under conditions of 121 ° C. and 100% RH, and then visually observed.
- the aluminum foil was completely peeled off.
- partial peeling of the aluminum foil was observed, but water did not penetrate to the center.
- the resin composition of the present invention using styrene-isobutylene modified resin adheres to the light extraction film and the transparent substrate with high adhesive strength, and also has adhesive strength even in harsh environments. It was shown that On the other hand, (A) the resin composition of Comparative Example 1 which uses an unmodified styrene-isobutylene-styrene copolymer without using a styrene-isobutylene-modified resin has a resistance to adhesion to a light extraction film and a transparent substrate. It was shown that the environmental properties are low and the resin composition for light extraction cannot be used.
- Example 2 A light extraction film was obtained by the method described below. Unless otherwise specified, the number of parts by mass (hereinafter abbreviated as “part”) of each component is a value converted in terms of solid content.
- Maleic anhydride-modified styrene-isobutylene-styrene block copolymer (T-YP926, 40% swazole-1000 solution) 23.1 parts is diluted with swathol-1000 (manufactured by Maruzen Petrochemical Co., Ltd.) 12.6 parts, and titanium oxide filler (SX3103) 8.2 parts were added and mixed so that no lumps remained.
- This mixture was further mixed for 30 minutes using a high-speed dispersion mixer (Ajihomo mixer, rotation speed 3000 rpm). This was designated as the first agent.
- Maleic anhydride-modified styrene-isobutylene-styrene block copolymer (T-YP926, 40% swazole-1000 solution) 40 parts, cyclohexyl ring-containing saturated hydrocarbon resin (Arcon P125), cyclohexyl ring-containing saturated hydrocarbon resin 20 parts of (Alcon P140) was added and dissolved by heating at 80 ° C. for 2 hours until uniform using a rotating mixer (planetary mixer, rotation speed 75 rpm). This was the second agent.
- the obtained varnish is coated on a PET film (Lumirror 38T6AM, manufactured by Toray Industries Inc.) with a hand coater at a coating thickness of 100 ⁇ m, heated in a 100 ° C. heat circulation oven for 30 minutes, and in a 130 ° C. heat circulation oven for 60 minutes.
- a light extraction film having a light extraction layer (thickness: 25 ⁇ m) formed on a PET film (thickness: 38 ⁇ m) was obtained.
- Examples 3 to 7, Comparative Examples 2 to 5> A varnish was obtained in the same manner as in Example 1 except that the formulation shown in the upper part of Table 1 below was changed, and the obtained varnish was applied on a PET film (Lumirror 38T6AM, manufactured by Toray Industries Inc.) with a hand coater at a coating thickness of 100 ⁇ m. It was coated and heated in a 100 ° C. heat circulation oven for 30 minutes and in a 130 ° C. heat circulation oven for 60 minutes, and a light extraction layer (thickness: 25 ⁇ m) was formed on the PET film (thickness: 38 ⁇ m). A film for light extraction was obtained.
- a PET film Limirror 38T6AM, manufactured by Toray Industries Inc.
- the tip of the light receiving fiber of a fiber type spectrophotometer (MCPD-7700, manufactured by Otsuka Electronics Co., Ltd.) was placed 75 mm away from the panel (transparent substrate) immediately above the center of the opening. And 4.5V was applied to the panel and the emission spectrum was acquired with the spectrophotometer.
- the spectrophotometer used the illuminant mode, and the received light intensity of each wavelength was measured in increments of 5 nm from 450 nm to 800 nm, and the value obtained by summing them was used as the panel emission intensity.
- the mask of the organic EL panel is removed, a 40 mm ⁇ 70 mm light extraction film is mounted on the surface of the organic EL panel, the mask is again masked according to the above procedure, and the emission intensity is obtained in the same manner. This was defined as the emission intensity when the film was mounted. Then, the front extraction efficiency was calculated by the following formula and evaluated according to the following evaluation criteria.
- Front extraction efficiency (Light emission intensity when film is mounted) / (Panel light emission intensity)
- the tip of the light receiving fiber of a fiber spectrophotometer (MCPD-7700, manufactured by Otsuka Electronics Co., Ltd.) was placed 75 mm away from the panel (transparent substrate) immediately above the center of the opening. 4.5V is applied to the panel, and the light receiving angle is changed in increments of 10 ° so as to draw a circle with a radius of 75 mm centered on the center of the opening, while the tip of the light receiving fiber always faces the center of the opening.
- MCPD-7700 fiber spectrophotometer
- the light receiving angle ⁇ here is an angle formed by a line perpendicular to the panel surface extending from the center of the opening to the light emitting surface side and a straight line connecting the tip of the light receiving fiber and the center of the panel light emitting part.
- the spectrophotometer with illuminant mode, and the panel light emission intensity L theta values obtained by aggregating them to measure the received light intensity of each wavelength at 5nm increments from 450nm to 800nm at an angle theta.
- the light distribution characteristic value was calculated as the degree of approach to the Lambert light distribution by the following equation, and evaluated according to the following evaluation criteria.
- the opening of the organic EL light emitting panel (manufactured by EL Techno Co., color temperature 3100K when 4.5V is applied) on which a film for extracting light of 40 mm ⁇ 70 mm is mounted.
- the tip of the light receiving fiber of a fiber type spectrophotometer (MCPD-7700, manufactured by Otsuka Electronics Co., Ltd.) was placed directly above the center at a distance of 75 mm from the panel (transparent substrate). Then, 4.5 V is applied to the panel, and the tip of the light receiving fiber is changed so as to draw a circle having a radius of 75 mm with the center of the opening as the center.
- a * and b * were obtained from the emission spectrum at 50 °, and were designated as an and b n , respectively. Note that a * and b * are chromaticity a * and b * in the L * a * b * color system defined in JIS Z 8729.
- the hue difference ⁇ H between 0 ° -50 ° was calculated from the following equation.
- ⁇ Total light transmittance> Attach a 550 nm total light transmittance spectrum of a sample with a 20 mm ⁇ 20 mm light extraction film attached to the center of a 25 mm ⁇ 25 mm ⁇ 1.1 mm thick slide glass (S1112, Matsunami Glass Industry Co., Ltd.), and a ⁇ 80 mm integrating sphere Measured using a fiber type spectrophotometer (MCPD-7700, manufactured by Otsuka Electronics Co., Ltd.). The reference was air.
- MCPD-7700 fiber type spectrophotometer
- the resin composition side of the 15 mm ⁇ 15 mm light extraction film was measured with a 2010M prism coupler (manufactured by Metricon) using a 589 nm laser beam at room temperature and normal pressure.
- the light extraction layer obtained from the resin composition of the present invention adheres to the transparent substrate with high adhesive force, and not only sufficiently enhances the light extraction efficiency of the light emitting device, but also has a light distribution characteristic and a hue difference. Greatly improved. Therefore, it is possible to realize a light emitting device (particularly, an organic EL device) that stably operates with high luminous efficiency over a long period of time and emits light that does not feel unnatural like natural light.
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Abstract
Description
[1] (A)スチレン-イソブチレン変性樹脂、(B)粘着付与樹脂、及び(C)フィラーを含むことを特徴とする、光取出し用樹脂組成物。
[2] (C)フィラーが、(A)スチレン-イソブチレン変性樹脂の屈折率よりも0.2以上大きい屈折率を有するフィラーである、上記[1]記載の樹脂組成物。
[3] (C)フィラーが、酸化チタン、酸化アルミニウム、酸化ジルコニウム、酸化セリウム、およびチタン酸バリウムから選択される少なくとも1種である、上記[1]または[2]に記載の樹脂組成物。
[4] (C)フィラーの平均粒径が0.5~50μmである、上記[1]~[3]のいずれか1つに記載の樹脂組成物。
[5] (A)スチレン-イソブチレン変性樹脂が、ポリスチレン骨格及びポリイソブチレン骨格を含むブロック共重合体であって、官能基を有するものである、上記[1]~[4]のいずれか1つに記載の樹脂組成物。
[6] 官能基が、酸無水物基、エポキシ基、カルボキシル基、アミノ基、水酸基、イソシアネート基、オキサゾリン基、オキセタン基、シアネート基、フェノール基、ヒドラジド基及びアミド基からなる群より選択される1種または2種以上である、上記[5]記載の樹脂組成物。
[7] (B)粘着付与樹脂が、脂環族系石油樹脂である、上記[1]~[6]のいずれか1つに記載の樹脂組成物。
[8] (B)粘着付与樹脂が、脂環族飽和炭化水素樹脂及び/又は脂環族不飽和炭化水素樹脂である、上記[1]~[6]のいずれか1つに記載の樹脂組成物。
[9] (B)粘着付与樹脂が、シクロヘキサン環含有飽和炭化水素樹脂及び/又はジシクロペンタジエン変性炭化水素樹脂である、上記[1]~[6]のいずれか1つに記載の樹脂組成物。
[10] (A)スチレン-イソブチレン変性樹脂の含有量が、樹脂組成物中の不揮発分全体当たり、35~80質量%である、上記[1]~[9]のいずれか1つに記載の樹脂組成物。
[11] (B)粘着付与樹脂の含有量が、樹脂組成物の不揮発分全体当たり、5~60質量%である、上記[1]~[10]のいずれか1つに記載の樹脂組成物。
[12] (C)フィラーの含有量が、樹脂組成物の不揮発分全体当たり、0.5~50質量%である、上記[1]~[11]のいずれか1つに記載の樹脂組成物。
[13] (D)硬化剤を更に含有する、上記[1]~[12]のいずれか1つに記載の樹脂組成物。
[14] 樹脂組成物の屈折率が1.45~1.60である、上記[1]~[13]のいずれか1つに記載の樹脂組成物。
[15] 発光デバイスの透明基板に積層される光取出し層用である、上記[1]~[14]のいずれか1つに記載の樹脂組成物。
[16] 発光デバイスが有機ELデバイスである、上記[15]に記載の樹脂組成物。
[17] 上記[1]~[13]のいずれか1つに記載の樹脂組成物を含むことを特徴とする、光取出し用フィルム。
[18] 全光線透過率が50~90%である、上記[17]記載の光取出し用フィルム。
[19] 屈折率が1.45~1.60である、上記[17]または[18]に記載の光取出し用フィルム。
[20] 上記[1]~[13]のいずれか1つに記載の樹脂組成物の層が透明フィルム上に形成されてなる、光取出し用フィルム。
[21] 発光デバイスの光取出し用である、上記[17]~[20]のいずれか1つに記載の光取出し用フィルム。
[22] 発光デバイスが有機ELデバイスである、上記[21]記載の光取出し用フィルム。
[23] 上記[1]~[13]のいずれか1つに記載の樹脂組成物からなる光取出し層を含む、発光デバイス。
[24] 光取出し層の全光線透過率が50~90%である、上記[23]に記載の発光デバイス。
[25] 光取出し層の屈折率が1.45~1.60である、上記[23]または[24]に記載の発光デバイス。
[26] 当該発光デバイスが有機ELデバイスである、上記[23]~[25]のいずれか1つに記載の発光デバイス。
(A)スチレン-イソブチレン変性樹脂、
(B)粘着付与樹脂、及び
(C)フィラー
を含むことが特徴である。
樹脂原料、樹脂組成物およびフィルムの屈折率:プリズムカップリング法により、屈折率のわかっているプリズムとそれに付着した試料との界面における臨界角を測定することで試料の屈折率を知ることができる。プリズムカップリング法測定装置としては、例えば、2010M型プリズムカプラ(メトリコン社製)を使用することができる。
フィラーの屈折率:液浸法により、予め屈折率のわかっている数種の浸漬液とフィラーを、定められた一つの混合比において混合した混合物の589nm平行線透過率を測定し、測定値の数字が最大となる浸漬液の屈折率をフィラーの屈折率とする。該混合物の混合比としては、該測定値の最大値が判別しやすいよう、適宜設定することができる。浸漬液としては、一般に入手可能な浸漬液を使用することができ、例えば、上記プリズムカップリング法を適用することによりあらかじめ屈折率が測定された1-ヨードナフタレン、ジヨードメタン等の任意の比率の混合物や、標準浸漬液を使用することができる。平行線透過率測定装置としては、一般に入手可能な分光光度計を使用することができ、例えばMCPD-7700(大塚電子社製)を使用することができる。ただし、フィラー屈折率が液浸法で測定可能な範囲を越える場合には、フィラーの主たる材質で構成されたバルク体に上記プリズムカップリング法を適用することで測定することができる。
本発明の樹脂組成物におけるスチレン-イソブチレン変性樹脂(以下、「(A)成分」ともいう)は、スチレン骨格及びイソブチレン骨格を含有する共重合体であり、官能基を有するものであれば、特に限定されない。共重合体の形態は、特に限定されず、ランダム共重合体、ブロック共重合体、グラフト共重合体等が挙げられる。かかるスチレン-イソブチレン変性樹脂は好ましくは室温(25℃)での状態が固体状である。
本発明の樹脂組成物中の(A)成分の含有量は特に制限はないが、樹脂組成物の成膜性(樹脂組成物のワニスの塗工性)、屈折率、常温における取扱い性等の観点から、(A)成分の含有量は樹脂組成物中の不揮発分全体当たり80質量%以下が好ましく、75質量%以下がより好ましく、70質量%以下が更に好ましい。一方、樹脂組成物の光学物性、発揮される光取出し性能等の観点から、(A)成分の含有量は樹脂組成物中の不揮発分全体当たり、35質量%以上が好ましく、40質量%以上がより好ましく、45質量%以上が更に好ましい。
本発明において使用される(B)粘着付与樹脂(以下、「(B)成分」とも略称する)は、タッキファイヤーとも呼ばれ、可塑性高分子に配合して粘着性を付与させる樹脂である。(B)成分としては、特に限定されるものではなく、テルペン樹脂、変性テルペン樹脂(水素添加テルペン樹脂、テルペンフェノール共重合樹脂、芳香族変性テルペン樹脂等)、クマロン樹脂、インデン樹脂、石油樹脂(脂肪族系石油樹脂、水添脂環式石油樹脂、芳香族系石油樹脂、脂肪族芳香族共重合系石油樹脂、脂環族系石油樹脂、ジシクロペンタジエン系石油樹脂およびその水素化物等)が好ましく使用される。なかでも、樹脂組成物の接着性、透明性、(A)成分との相溶性等の観点から、テルペン樹脂、芳香族変性テルペン樹脂、テルペンフェノール共重合樹脂、水添脂環式石油樹脂、芳香族系石油樹脂、脂肪族芳香族共重合系石油樹脂、脂環族系石油樹脂がより好ましく、脂環族系石油樹脂が更に好ましく、脂環族飽和炭化水素樹脂、脂環族不飽和炭化水素樹脂が更に一層好ましく、シクロヘキシル環含有飽和炭化水素樹脂が最も好ましい。(B)成分は1種又は2種以上を組み合わせて使用してもよい。
本発明において使用されるフィラー(以下、「(C)成分」とも略称する)は(A)成分のスチレン-イソブチレン変性樹脂の屈折率よりも屈折率が0.2以上大きいフィラーであれば、無機フィラー、有機フィラーのいずれも使用可能である。樹脂組成物がスチレン-イソブチレン変性樹脂の屈折率よりも屈折率が0.2以上大きいフィラーを含むことで、フィラーとスチレン-イソブチレン変性樹脂の界面で充分な光反射や散乱が起こって、十分に高い光取出し効果が得られる光取出し層を形成することができる。フィラーの屈折率は、スチレン-イソブチレン変性樹脂の屈折率よりも0.22以上大きいことが好ましく、0.25以上大きいことがより好ましい。フィラーとスチレン-イソブチレン変性樹脂の屈折率の差の上限に特に制限は無いが、コスト等の観点から、1.0以下が好ましい。
本発明の樹脂組成物には、更に硬化剤(以下、「(D)成分」とも略称する)を含有させることができる。なお、硬化剤(架橋剤)は、(A)成分が有する官能基に応じて、適宜、含有される。硬化剤(架橋剤)の使用は、(A)成分として、エポキシ基を有するスチレン-イソブチレン変性樹脂を含む場合に好適である。従って、硬化剤としては、アミン系硬化剤、グアニジン系硬化剤、イミダゾール系硬化剤、ホスホニウム系硬化剤、フェノール系硬化剤などのエポキシ硬化剤が挙げられる。(D)成分は1種又は2種以上を使用できる。
例えば、本発明の樹脂組成物を溶剤に溶解乃至分散させたワニスを調製し、発光デバイスの透明基板上に、ワニスを塗布、乾燥して樹脂組成物層を形成することで、当該樹脂組成物層が透明基板に高い接着力にて密着した光取出し層となる。乾燥条件は特に制限はないが、50~100℃で1~60分が好ましい。また、樹脂組成物層はさらに加熱して硬化物としてもよい。
本発明の光取出し用フィルムは、本発明の樹脂組成物からなる単層フィルム、および、本発明の樹脂組成物の層(光取出し層)が透明フィルム上に形成された多層フィルムの形態を含む。単層フィルムは、公知のフィルム成形法によって、本発明の樹脂組成物をフィルムに成形するか、本発明の樹脂組成物を溶剤に溶解乃至分散させたワニスを適当な基材(好ましくは剥離処理した基材)に塗工し、乾燥し、乾燥後の被膜を剥離する等の方法によって、得ることができる。また、多層フィルムは、本発明の樹脂組成物を溶剤に溶解乃至分散させたワニスを透明フィルム上に塗工し、乾燥することによって、得ることができる。
なお、本発明でいう、「光取出し用フィルムの厚さ、全光線透過率および屈折率」とは、光取出し用フィルムが単層フィルムの場合は、単層フィルムの厚さ、全光線透過率および屈折率であり、多層フィルムの場合は、本発明の樹脂組成物の層(光取出し層)の厚さ、全光線透過率および屈折率を意味する。
すなわち、支持体であるフィルム(第一のフィルム)の片面に樹脂組成物層(光取出し層)を形成した樹脂組成物層転写用フィルムを樹脂組成物層側を透明基板に向けて透明基板に熱ラミネートした後、該フィルムを剥離して、透明基板に残留した樹脂組成物層(透明基板に転写させた樹脂組成物層)に透明フィルム(第二のフィルム)を熱ラミネートすることで、透明基板に高い接着力にて密着した樹脂組成物層(光取出し層)が透明フィルムで覆われた光取出し構造が形成される。
本発明でいう発光デバイスとは、有機ELデバイス、無機ELデバイス、LED、蛍光管等を含む概念であり、典型的には、有機EL照明デバイス(パネル・モジュール)、LED照明デバイス等の照明用途の発光デバイスである。
(A)スチレン-イソブチレン変性樹脂
・T-YP926(星光PMC社製):無水マレイン酸変性スチレン-イソブチレン-スチレンブロック共重合体、無水マレイン酸基(酸無水物基)濃度:0.45mmol/g、数平均分子量:35,000、屈折率(25℃、589nm):1.52
・T-YP927(星光PMC社製):グリシジルメタクリレート変性スチレン-イソブチレン-スチレンブロック共重合体、グリシジル基(エポキシ基)濃度:0.64mmol/g、数平均分子量:48,000、屈折率(25℃、589nm):1.52
(B)粘着付与樹脂
・アルコンP125(荒川化学工業社製):シクロヘキシル環含有飽和炭化水素樹脂、軟化点125℃、屈折率(25℃、589nm):1.53
・アルコンP140(荒川化学工業社製):シクロヘキシル環含有飽和炭化水素樹脂、軟化点140℃、屈折率(25℃、589nm):1.53
(C)フィラー
・SX3103(堺化学社製):酸化チタン、屈折率:2.4、平均粒径:2.0μm
・AA-3(住友化学社製):酸化アルミニウム、屈折率:1.78、平均粒径:3.0μm
・DSN-30(根本特殊化学社製):炭酸カルシウム、屈折率:1.66(常光線に対して)、平均粒径:12μm
(D)硬化剤
・TAP(化薬アグゾ社製):2,4,6-トリス(ジメチルアミノメチル)フェノール
以下に記載の方法で光取出し用フィルムを得た。なお、特に記載のない限り、各成分の質量部(以下、「部」と略称する)の部数は固形分で換算した値である。
無水マレイン酸変性スチレン-イソブチレン-スチレンブロック共重合体(T-YP926、40%スワゾール-1000溶液)23.1部をスワゾール-1000(丸善石油化学製)12.6部で希釈し、酸化チタンフィラー(SX3103)3.0部を添加してダマ残りのないよう混合した。この混合物を、さらに高速分散ミキサー(アジホモミキサー、回転数3000rpm)を用いて30分混合した。これを第1剤とした。
無水マレイン酸変性スチレン-イソブチレン-スチレンブロック共重合体(T-YP926、40%スワゾール-1000溶液)40部に、シクロヘキシル環含有飽和炭化水素樹脂(アルコンP125)60部、シクロヘキシル環含有飽和炭化水素樹脂(アルコンP140)20部を加え、回転ミキサー(プラネタリーミキサー、回転数75rpm)を用いて均一となるまで80℃で2時間加熱溶解させた。これを第2剤とした。
無水マレイン酸変性スチレン-イソブチレン-スチレンブロック共重合体(T-YP926、40%スワゾール-1000溶液)およびリシジルメタクリレート変性スチレン-イソブチレン-スチレンブロック共重合体(T-YP927、40%スワゾール-1000溶液)を、ともにスチレン-イソブチレン-スチレン共重合体(SIBSTAR-102T、40%スワゾール-1000溶液)に変更した以外は、実施例1と同様にして光取出し用フィルムを得た。
実施例1及び比較例1の光取出し用フィルム(長さ50mm、幅20mm)をバッチ式真空ラミネーター(ニチゴー・モートン社製、Morton-724)を用いて、アルミニウム箔(長さ100mm、幅20mm、厚さ50μm、住軽アルミ箔社製、品番SA50)にラミネートした。ラミネートは、温度80℃、時間20秒、圧力1kgf/cm2(9.8×104Pa)の条件で行った。そしてPETフィルムを剥離し、露出した樹脂組成物層(光取出し層)上に、さらにガラス板(長さ76mm、幅26mm、厚さ1.2mm、マイクロスライドガラス)を上記と同じ条件でラミネートした。得られた積層体を、121℃、100%RHの条件下で24時間保持した後に、目視観察したところ、比較例1の光取出し用フィルムによる積層体では、アルミニウム箔が完全に剥離していたが、実施例1の光取出し用フィルムによる積層体では、アルミニウム箔の部分的な剥離が認められたが、水は中央部まで浸透していなかった。
以下に記載の方法で光取出し用フィルムを得た。なお、特に記載のない限り、各成分の質量部(以下、「部」と略称する)の部数は固形分で換算した値である。
無水マレイン酸変性スチレン-イソブチレン-スチレンブロック共重合体(T-YP926、40%スワゾール-1000溶液)23.1部をスワゾール-1000(丸善石油化学製)12.6部で希釈し、酸化チタンフィラー(SX3103)8.2部を添加してダマ残りのないよう混合した。この混合物を、さらに高速分散ミキサー(アジホモミキサー、回転数3000rpm)を用いて30分混合した。これを第1剤とした。
無水マレイン酸変性スチレン-イソブチレン-スチレンブロック共重合体(T-YP926、40%スワゾール-1000溶液)40部に、シクロヘキシル環含有飽和炭化水素樹脂(アルコンP125)60部、シクロヘキシル環含有飽和炭化水素樹脂(アルコンP140)20部を加え、回転ミキサー(プラネタリーミキサー、回転数75rpm)を用いて均一となるまで80℃で2時間加熱溶解させた。これを第2剤とした。
下記表1の上段に示す処方に変更した以外は実施例1と同様にしてワニスを得、得られたワニスを、ハンドコーターにてPETフィルム(ルミラー38T6AM、東レ製)上に塗工厚100μmで塗工し、100℃の熱循環オーブンで30分、130℃の熱循環オーブンで60分加熱して、PETフィルム(厚さ:38μm)上に光取出し層(厚さ:25μm)が形成された光取出し用フィルムを得た。
平面形状が40mm×70mmの長方形のパネル体の中心に発光部(27mm×48mmの矩形領域)を持つ有機EL発光パネル(イー・エル・テクノ製、4.5V印加のとき色温度3100K)を用意し、該有機EL発光パネルの透明基板の表面の中心部の15mm×15mmの正方形領域が開口部となるように、該表面のその他の領域を黒色紙でマスクした。この開口部の中心の直上にファイバ式分光光度計(MCPD-7700、大塚電子製)の受光ファイバの先端をパネル(透明基板)から75mm離間させて設置した。そして、パネルに4.5Vを印加して、分光光度計により発光スペクトルを取得した。なお、分光光度計は発光体モードを用い、450nmから800nmまで5nm刻みで各波長の受光強度を測定してそれらを集計した値をパネル発光強度とした。次に、上記有機ELパネルのマスクを取り外し、該有機ELパネルの表面に40mm×70mm光取出し用フィルムを装着し、その上に上記手順に従って再度マスクをした後、同様の操作で発光強度を取得し、これをフィルム装着時発光強度とした。そして、次式により正面取出し効率を算出し、下記の評価基準で評価した。
優秀(◎):140%以上
良好(○):130%以上、140%未満
可(△):120%以上、130%未満
不可(×):120%未満
平面形状が40mm×70mmの長方形のパネル体の中心に発光部(27mm×48mmの矩形領域)を持つ有機EL発光パネル(イー・エル・テクノ製、4.5V印加のとき色温度3100K)に、40mm×70mmの光取出し用フィルムを装着し、該有機EL発光パネルの透明基板の表面の中心部の15mm×15mmの正方形領域が開口部となるように、該表面のその他の領域を黒色紙でマスクした。この開口部の中央の直上にファイバ式分光光度計(MCPD-7700、大塚電子製)の受光ファイバの先端をパネル(透明基板)から75mm離間させて設置した。パネルに4.5Vを印加し、受光ファイバの先端が常に開口部の中心を向くようにしながら、開口部の中心を中心とした半径75mmの円を描くように受光角度を10°刻みで変動させることで、0°から70°までの受光角度θにおける発光スペクトルを取得した。ここでいう受光角度θとは、開口部の中心を原点とし光放出面側に延びるパネル面に垂直な線と、受光ファイバの先端とパネル発光部位中心を結ぶ直線の成す角度のことである。
なお、分光光度計は発光体モードを用い、450nmから800nmまで5nm刻みで各波長の受光強度を測定してそれらを集計した値を角度θにおけるパネル発光強度Lθとした。次式によりランバート配光への接近度合いとして配光分布特性値を算出し、下記の評価基準で評価した。
優秀(◎):1.200未満
良好(○):1.200以上、1.225未満
可(△):1.225以上、1.250未満
不可(×):1.250以上
配光分布特性の評価試験と同様にして、40mm×70mmの光取出し用フィルムが装着された有機EL発光パネル(イー・エル・テクノ製、4.5V印加のとき色温度3100K)の開口部の中央の直上にファイバ式分光光度計(MCPD-7700、大塚電子製)の受光ファイバの先端をパネル(透明基板)から75mm離間させて設置した。そして、パネルに4.5Vを印加し、受光ファイバの先端を、開口部の中心を中心とした半径75mmの円を描くように変動させ、受光角度0°における発光スペクトルよりa*、b*を取得し、それぞれa0、b0とした。同様に、50°における発光スペクトルよりa*、b*を取得し、それぞれan、bnとした。なお、a*、b*はJIS Z 8729に規定のL*a*b*表色系における色度a*、b*である。
優秀(◎):1.0未満
良好(○):1.0以上、1.5未満
可(△):1.5以上、2.0未満
不可(×):2.0以上
25mm×25mm×1.1mm厚のスライドガラス(S1112、松浪硝子工業社製)の中心に20mm×20mmの光取出し用フィルムを貼り付けたサンプルの550nm全光線透過率スペクトルを、φ80mm積分球を装着したファイバ式分光光度計(MCPD-7700、大塚電子社製)を用いて測定した。リファレンスは空気とした。
15mm×15mmの光取出し用フィルムの樹脂組成物面側を2010M型プリズムカプラ(メトリコン製)により589nmレーザー光を用い室温常圧下で測定した。
Claims (26)
- (A)スチレン-イソブチレン変性樹脂、
(B)粘着付与樹脂、及び
(C)フィラー
を含むことを特徴とする、光取出し用樹脂組成物。 - (C)フィラーが、(A)スチレン-イソブチレン変性樹脂の屈折率よりも0.2以上大きい屈折率を有するフィラーである、請求項1記載の樹脂組成物。
- (C)フィラーが、酸化チタン、酸化アルミニウム、酸化ジルコニウム、酸化セリウム、およびチタン酸バリウムから選択される少なくとも1種である、請求項1または2に記載の樹脂組成物。
- (C)フィラーの平均粒径が0.5~50μmである、請求項1~3のいずれか1項に記載の樹脂組成物。
- (A)スチレン-イソブチレン変性樹脂が、ポリスチレン骨格及びポリイソブチレン骨格を含むブロック共重合体であって、官能基を有するものである、請求項1~4のいずれか1項に記載の樹脂組成物。
- 官能基が、酸無水物基、エポキシ基、カルボキシル基、アミノ基、水酸基、イソシアネート基、オキサゾリン基、オキセタン基、シアネート基、フェノール基、ヒドラジド基及びアミド基からなる群より選択される1種または2種以上である、請求項5記載の樹脂組成物。
- (B)粘着付与樹脂が、脂環族系石油樹脂である、請求項1~6のいずれか1項に記載の樹脂組成物。
- (B)粘着付与樹脂が、脂環族飽和炭化水素樹脂及び/又は脂環族不飽和炭化水素樹脂である、請求項1~6のいずれか1項に記載の樹脂組成物。
- (B)粘着付与樹脂が、シクロヘキサン環含有飽和炭化水素樹脂及び/又はジシクロペンタジエン変性炭化水素樹脂である、請求項1~6のいずれか1項に記載の樹脂組成物。
- (A)スチレン-イソブチレン変性樹脂の含有量が、樹脂組成物中の不揮発分全体当たり、35~80質量%である、請求項1~9のいずれか1項に記載の樹脂組成物。
- (B)粘着付与樹脂の含有量が、樹脂組成物の不揮発分全体当たり、5~60質量%である、請求項1~10のいずれか1項に記載の樹脂組成物。
- (C)フィラーの含有量が、樹脂組成物の不揮発分全体当たり、0.5~50質量%である、請求項1~11のいずれか1項に記載の樹脂組成物。
- (D)硬化剤を更に含有する、請求項1~12のいずれか1項に記載の樹脂組成物。
- 樹脂組成物の屈折率が1.45~1.60である、請求項1~13のいずれか1項に記載の樹脂組成物。
- 発光デバイスの透明基板に積層される光取出し層用である、請求項1~14のいずれか1項に記載の樹脂組成物。
- 発光デバイスが有機ELデバイスである、請求項15に記載の樹脂組成物。
- 請求項1~13のいずれか1項に記載の樹脂組成物を含むことを特徴とする、光取出し用フィルム。
- 全光線透過率が50~90%である、請求項17記載の光取出し用フィルム。
- 屈折率が1.45~1.60である、請求項17または18に記載の光取出し用フィルム。
- 請求項1~13のいずれか1項に記載の樹脂組成物の層が透明フィルム上に形成されてなる、光取出し用フィルム。
- 発光デバイスの光取出し用である、請求項17~20のいずれか1項に記載の光取出し用フィルム。
- 発光デバイスが有機ELデバイスである、請求項21記載の光取出し用フィルム。
- 請求項1~13のいずれか1項に記載の樹脂組成物からなる光取出し層を含む、発光デバイス。
- 光取出し層の全光線透過率が50~90%である、請求項23に記載の発光デバイス。
- 光取出し層の屈折率が1.45~1.60である、請求項23または24に記載の発光デバイス。
- 当該発光デバイスが有機ELデバイスである、請求項23~25のいずれか1項記載の発光デバイス。
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Also Published As
| Publication number | Publication date |
|---|---|
| KR20160030259A (ko) | 2016-03-16 |
| TW201516127A (zh) | 2015-05-01 |
| JP6269669B2 (ja) | 2018-01-31 |
| JPWO2015005464A1 (ja) | 2017-03-02 |
| TWI638027B (zh) | 2018-10-11 |
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