JP6195099B2 - 封止材フィルム及びこれを含む電子装置 - Google Patents
封止材フィルム及びこれを含む電子装置 Download PDFInfo
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- JP6195099B2 JP6195099B2 JP2016521207A JP2016521207A JP6195099B2 JP 6195099 B2 JP6195099 B2 JP 6195099B2 JP 2016521207 A JP2016521207 A JP 2016521207A JP 2016521207 A JP2016521207 A JP 2016521207A JP 6195099 B2 JP6195099 B2 JP 6195099B2
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- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
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- 125000003808 silyl group Chemical group [H][Si]([H])([H])[*] 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
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- 235000011152 sodium sulphate Nutrition 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
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- 150000003505 terpenes Chemical class 0.000 description 1
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- 239000008096 xylene Substances 0.000 description 1
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- 239000010457 zeolite Substances 0.000 description 1
Classifications
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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
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
- C08L23/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
- C08L23/22—Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefins
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- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C08L101/00—Compositions of unspecified macromolecular compounds
- C08L101/02—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/29—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the material, e.g. carbon
- H01L23/293—Organic, e.g. plastic
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- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/846—Passivation; Containers; Encapsulations comprising getter material or desiccants
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- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K85/00—Organic materials used in the body or electrodes of devices covered by this subclass
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- H10K85/151—Copolymers
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- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
- C08J2323/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
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- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2423/26—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers modified by chemical after-treatment
- C08J2423/30—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers modified by chemical after-treatment by oxidation
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- C08L2205/00—Polymer mixtures characterised by other features
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- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
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- Computer Hardware Design (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Optics & Photonics (AREA)
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Electroluminescent Light Sources (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
- Photovoltaic Devices (AREA)
Description
i)アルキル化触媒の存在下の反応性ポリイソブチレンと芳香族ヒドロキシ化合物の反応によりポリイソブチレンでアルキル化された芳香族ヒドロキシ化合物を提供、
ii)反応性ポリイソブチレンとパーオキシ化合物の反応によりエポキシド化されたポリイソブチレンを提供、
iii)反応性ポリイソブチレンと置換された二重結合を有するアルケンの反応、
iv)ヒドロホルミル化触媒の存在下の反応性ポリイソブチレンと一酸化炭素及び水素の反応によりヒドロホルミル化されたポリイソブチレンを提供、
v)反応性ポリイソブチレンとリンハライドまたはオキシ塩化リンの反応によりホスホノ基で官能化されたポリイソブチレンを提供、
vi)反応性ポリイソブチレンとボランの反応及び後続の酸化性分解によりヒドロキシル化されたポリイソブチレンを提供、
vii)反応性ポリイソブチレンとSO3供給源、例えばアセチルスルフェートの反応により末端スルホン基を有するポリイソブチレンを提供、
viii)反応性ポリイソブチレンと窒素の酸化物の反応及び後続の水素化反応により末端アミノ基を有するポリイソブチレンを提供、
ix)反応性ポリイソブチレンと硫化水素またはチオールの反応によりチオール基で官能化されたポリイソブチレンを提供。
R−X
例えば、まず、水分遮断剤を溶媒に投入し、第1分散液を製造することができる。この際、第1分散液は、音波処理、ビーズミリング、ボールミリング、高速分散、高圧分散などの工程を通して均一に分散した分散液として得られることができる。これとは別途に、前述したように、水分吸収剤及び/または分散剤が分散した第2分散液を用意する。用意した第1分散液と第2分散液を、樹脂成分を含む溶液に投入し、混合する。混合時に樹脂組成物の粘度調節及びコーティング性を考慮して、さらに溶媒を投入してもよい。このような方法によって水分吸収剤及び遮断剤が均一に分散したフィルムを製造することができる。上記製造方法は、当業者によって自明な事項内で自由に変更が可能である。
DnSiQ(4−n)
本出願の封止材フィルムは、ベース樹脂及び極性官能基を有する添加剤を含み、これによって、高温高湿条件での接着信頼性を確保することができると共に、上記極性官能基を有する添加剤のバックボーン(backbone)がベース樹脂と相溶性を有することによって、フィルムの光学特性の低下がなく、水分遮断性能の低下がない。したがって、上記フィルムは、例えば、大面積の装置で素子の保護のために適用される場合にも、気泡などの誘発なしに素子上に積層されることができ、封止工程後に外部成分、例えば、水分などから素子を効果的に保護することができる。
Pr≧2000gf/in
Ph≧500gf/in
実施例または比較例の粘着剤組成物で粘着層の厚さが約50μmとなるように粘着フィルムを製造した。製造された粘着フィルムを離型処理されないPET基材フィルムとラミネーションし、幅が1インチであり、長さが20cmとなるように裁断した。次いで、粘着フィルムの離型処理された基材フィルムを剥離し、粘着層をガラス板の上に付着し、試験片を準備した。次に、texture analyzerを利用して10mm/secの剥離速度及び180゜の剥離角度で剥離しながら、試験片の180゜剥離力を測定した。
接着信頼性を判断するために、追加的にサンプルを85℃、85%相対湿度が維持されるオーブンで100時間放置した後、高温/高湿下での剥離力の変化を調べた。
実施例で使用したベース樹脂または比較例で使用された樹脂を溶媒に溶解し、樹脂組成物を製造した。上記樹脂組成物を厚さ38μmの基材フィルム(離型ポリエステルフィルム、RS−21G、SKC製)に塗布した。次いで、110℃で10分間乾燥し、厚さが100μmであるフィルム形状の層を製造した。各組成物のフィルムを架橋条件によって架橋させた後、基材フィルムを剥離し、フィルム形状の層を100°F及び100%の相対湿度に位置させた状態で、上記フィルム形状の層の厚さ方向に対する透湿度を測定した。上記透湿度は、ASTM F1249での規定によって測定した。
12mm×12mm(長さ×幅)のサイズのガラス基板にカルシウム(Ca)を10mm×10mm(長さ×幅)のサイズで蒸着した。これとは別途に、実施例または比較例で製造したフィルムを12mm×12mm(長さ×幅)のサイズで裁断した。次いで、フィルムの片面をカバーガラスに転写させた。次に、フィルムのカバーガラスが存在する面の反対面を上記ガラス基板のカルシウム上にラミネートし、オートクレーブを使用して、50℃及び5気圧条件で加熱圧着した後、組成によって、100℃で1時間硬化させるか、紫外線を2J/cm2の光量で照射し、硬化させることによって、封止層を形成し、試験片を製造した。その後、試験片を85℃及び85%相対湿度の恒温恒湿チャンバで約500時間維持しながら、上記カルシウム蒸着部分が酸化し、透明に変化した長さを測定した。カルシウムは、一方向への全体長さが10mmなので、カルシウムの一端から酸化した部分の長さが5mmになれば、カルシウムはすべて酸化する。
上記実施例で製造したフィルムを100mm×100mmサイズで裁断し、真空ラミネータ(LM−30×30−S、NPC社)を利用して150℃の下で10分間ラミネーションし、試験片を製作した。ラミネーションされた試験片をHazemeter(NDH−5000)を利用してJIS K 7105方法に基づいて光透過度を測定した。上記透過度の場合、水分吸収剤が添加されない状態での光透過度を測定した。
水分吸収剤として焼成ドロマイト100重量部及び分散剤としてステアリン酸0.5重量部をトルエンに固形分50重量%の濃度で投入して水分吸収剤溶液を製造し、上記溶液をボールミル工程によって24時間ミリングした。また、これとは別途に、常温で反応器にベース樹脂として重量平均分子量110万のポリイソブチレン樹脂(商品名:B100、製造社:BASF)100重量部及びポリイソブテニルコハク酸無水物(polyisobutenyl succinic anhydride:PIBSA)20重量部を投入し、硬化剤として2−エチル−4−メチルイミダゾール2重量部、熱硬化性樹脂としてトリメチロールプロパントリグリシジルエーテル10重量部、粘着付与剤として水素化されたジシクロペンタジエン系樹脂(商品名:SU−90、製造社:コーロング)30重量部を投入した後、トルエンで固形分が20重量%程度となるように希釈した。その後、反応器の内部を窒素で置換し、製造された溶液を均質化した。上記均質化された溶液にあらかじめ準備した水分吸収剤溶液を焼成ドロマイトの含量がベース樹脂100重量部に対して50重量部となるように投入し、混合して組成物を製造した。
上記で製造した組成物を離型PETの離型面に塗布し、110℃に10分間乾燥し、厚さが50μmのフィルムを形成した。上記フィルムの熱硬化条件は、100℃で1時間熱硬化させた。
ポリイソブチレン樹脂を100重量部、ポリイソブテニルコハク酸無水物を10重量部で使用したことを除いて、実施例1と同一に行い、フィルムを製造した。
ポリイソブテニルコハク酸無水物の代わりに、ポリイソブテニルアミン20重量部を添加したことを除いて、実施例1と同一に行い、フィルムを製造した。
熱硬化剤の代わりに、ラジカル開始剤として1−ヒドロキシ−シクロヘキシル−フェニルケトン(BASF、Igacure 184)の含量を1重量部を使用し、熱硬化性樹脂の代わりに、光硬化性アクリレートとしてトリメチロールプロパントリアクリレートの含量を10重量部を使用したことを除いて、実施例1と同一に行い、フィルムを製造した。上記フィルムの光硬化は、紫外線を2J/cm2の光量で照射して行った。
ポリイソブテニルコハク酸無水物を使用せず、ポリイソブチレン樹脂を100重量部で使用したことを除いて、実施例1と同一に行い、フィルムを製造した。
常温で反応器にシラン変性エポキシ樹脂(KSR−177、国都化学)100重量部及びフェノキシ樹脂(YP−50、東都化成)60重量部を添加し、メチルエチルケトンで希釈した。上記均質化された溶液に硬化剤である2−エチル−4−メチルイミダゾール(四国化成)10重量部を投入した後、1時間高速撹拌した。上記均質化された溶液にあらかじめ準備した水分吸収剤溶液を、焼成ドロマイトの含量をシラン変性エポキシ樹脂100重量部に対して50重量部となるように投入し、混合し、組成物を製造した。
上記で製造した組成物を離型PETの離型面に塗布し、110℃で10分間乾燥し、厚さが50μmのフィルムを形成した。上記フィルムの熱硬化条件は、100℃で3時間熱硬化させた。
ポリイソブテニルコハク酸無水物の代わりに、ポリエステルアクリレート接着増進剤(Sartomer、CN704)10重量部を添加したことを除いて、実施例1と同一に行い、フィルムを製造した。
Claims (12)
- 下記化学式1の繰り返し単位を有するベース樹脂と、化学式2で表示される化合物を有する添加剤とを含む第1層、及び
硬化性樹脂組成物を含む第2層、を含む封止材フィルム:
R1及びR2は、それぞれ独立に、水素または炭素数1〜12のアルキル基であり、
nは、1以上であり、
R1及びR2は、化学式1で定義した通りであり、
Lは、アルキレン、アリレン、エーテル、エステル、カルボニル、アリル、アルキルアリル及びアルケニレンよりなる群から選択された1種以上またはこれらの組み合わせよりなる有機リンカーまたは単一結合であり、
Pは、極性官能基を示し、
前記極性官能基は、酸無水物基、アミド基、アルコキシ基、アルコール基、アルデヒド基、カルボニル基、カルボキシ基、エステル基、エーテル基、エポキシ基、アミノ基、スルホン基、ヒドロキシ基及びマレイン酸基よりなる群から選択される1種以上であり、
nは、1以上である。 - 添加剤はベース樹脂と相溶性を有する、請求項1に記載の封止材フィルム。
- ベース樹脂は、ポリイソブチレンまたはイソブチレンを90mol%以上含む共重合体である、請求項1に記載の封止材フィルム。
- 添加剤は、ポリイソブテニルコハク酸無水物、ポリイソブテニルアミン及びポリイソブテニルアルコールよりなる群から選択された1種以上である、請求項1に記載の封止材フィルム。
- ベース樹脂の重量平均分子量が10万〜200万である、請求項3に記載の封止材フィルム。
- 上記ベース樹脂100重量部に対して1〜50重量部の添加剤を含む、請求項1に記載の封止材フィルム。
- 水分吸収剤をさらに含む、請求項1に記載の封止材フィルム。
- ベース樹脂100重量部に対して水分吸収剤を1重量部〜100重量部で含む、請求項7に記載の封止材フィルム。
- 下記一般式1を満足する、請求項1に記載の封止材フィルム:
[一般式1]
Pr≧2000gf/in
上記一般式1で、Prは、常温で10mm/secの剥離速度及び180゜の剥離角度で測定した上記封止材フィルムのガラスに対する上記封止材フィルムの剥離力を示す。 - 下記一般式2を満足する、請求項1に記載の封止材フィルム:
[一般式2]
Ph≧500gf/in
上記一般式2で、Phは、85℃及び85%の相対湿度条件で24〜100時間維持した後、10mm/secの剥離速度及び180゜の剥離角度で測定した上記封止材フィルムのガラスに対する上記封止材フィルムの剥離力を示す。 - 上記封止材フィルムの100゜F及び100%の相対湿度条件での水分透過度が10g/m2・day未満である、請求項1に記載の封止材フィルム。
- 上部基板と;下部基板と;上記上部基板と下部基板との間で素子を封止している請求項1に記載のフィルムと;を含む電子装置。
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