LED用高折射率光学树脂的制备与性能研究
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摘要
高折射率光学树脂用于发光二极管（LED）封装时，可以使LED芯片免受应力冲击和水汽侵蚀，能改善光取出效率、减少发热和延长使用寿命。研究表明，分子结构中以硫醇或硫醚基团引入硫原子是提高聚合物折射率最有效的方法之一。然而，现已报道的高折射率光学树脂存在价格高、稳定性差、或难以加工的问题，有必要研究成本适中和综合性能良好的高折射率光学树脂。
采用4,4'-二巯基二苯硫醚和4,4'-二羟基二苯硫醚，通过二步法，分别合成了高折射率的二巯基二苯硫醚环氧预聚物（DGETDBT）和二羟基二苯硫醚环氧预聚物（DGETP）。通过傅里叶变换红外光谱仪（FTIR）和核磁共振仪的氢谱（1H NMR）表征合成产物的分子结构,用差示扫描量热仪（DSC）、热重分析仪（TGA）、热机械分析仪（TMA）、紫外可见光谱仪和阿贝折射仪分析环氧预聚物、环氧混合物及其固化物的光学性能、热性能和热稳定性，并与普通的双酚A环氧预聚物（DGEBA）的相应性能进行对比。分析表明，DGETDBT和DGETP的折射率分别为1.665和1.612，与间苯二甲胺（MXDA）固化反应得到的固化物折射率分别为1.698和1.645，与甲基六氢苯酐（MHHPA）固化反应得到的固化物折射率分别为1.628和1.595，高于DGEBA相应的1.570、1.604和1.568，表明硫原子对提高折射率有很大帮助。DGETDBT、DGETP和DGEBA与MXDA反应的固化物可见光透光率均超过85%，与MHHPA反应的固化物相应值超过88%。DGETDBT/MXDA和DGETDBT/MHHPA固化物透光率为零的区域为200~370nm和200~390nm。透光率为零的区域覆盖紫外线谱带有利于防止LED发出的紫外线泄露，保护人眼免受紫外线伤害。DGETDBT、DGETP和DGEBA固化时表现出同样的放热行为，与MXDA及MHHPA反应得到的固化物T1均超过250℃，明显高于LED的正常使用温度。DGETP价格适中，折射率为1.612，其他性能不低于DGEBA，有望成为LED的高效封装树脂。
硫醇类固化剂折射率高，固化速率快，且能提高固化产物的韧性。脂肪硫醇可通过硫脲法合成，合成过程比苯硫酚的合成过程简单。采用硫脲法合成邻苯二甲硫醇（OBDMT），FTIR和1H NMR表征合成产物的分子结构。OBDMT为无色晶体，折射率为1.628。DGETP/OBDMT固化物的折射率为1.654，透光性超过85%，玻璃化转变温度为28.7℃。DGETP/MHHPA固化物的折射率为1.595，透光性超过88%，玻璃化转变温度为64.9℃。对于同一种环氧树脂，OBDMT固化物比MHHPA固化物具有更高的折射率。
采用点击化学法，季戊四醇四丙烯酸酯（PETTA）分别与季戊四醇四巯基乙酸酯（PETTG）和OBDMT反应，通过热固化和紫外光固化两种工艺，制备PETTA/PETTG固化物和PETTA/OBDMT固化物。PETTA/OBDMT固化物的折射率为1.597，透光率基本超过85%，1%的热失重温度达237.8℃。PETTA/PETTG固化物的透光率最高达93%，1%的热失重温度达324.2℃，可以媲美有机硅封装树脂，其折射率为1.556，高于大部分有机硅封装树脂的1.410~1.530。
原位分析及拟合结果表明，折射率随着固化时间或者固化度呈明显的指数关系。在固化初始阶段，分子数目变化较快，体积收缩较大，因此折射率变化较快；在中后期阶段，分子数目变化不是特别明显，固化体系的体积收缩也较小，折射率增加不明显。这一结果与经典电磁学理论得到的Lorentz-Lorenz关系式相一致，即折射率受摩尔体积和摩尔折射率两者影响。
由FTIR法、Kissinger法和Ozawa法得到的DGETP/三乙烯四胺（TETA）混合物的固化表观活化能分别为52.6kJ·mol~(-1)、56.3kJ·mol~(-1)和59.3kJ·mol~(-1)，三个结果相近，可以相互验证。非等温DSC固化动力学研究表明，OBDMT固化DGETP的活化能最低，TETA的次之，MHHPA的最大。OBDMT固化DGETP的反应级数与TETA的相等，而MHHPA的反应级数则不相同，固化曲线上也表明这一点。DGEBA和DGETBBA的固化活化能、固化起点温度和峰值温度均较高，DGETP和DGETDBT的固化活化能、固化起点温度以及固化峰值温度均较低。
针对LED的发热问题，采用乙烯-辛烯共聚物（POE）、乙烯-醋酸乙烯酯共聚物（EVA）、三元乙丙橡胶（EPDM）等热塑性弹性体分别与石蜡一起制备定形相变材料。用耐热实验、耐热水实验和温度循环实验测试它们的稳定性，用DSC求取它们的热焓。结果表明，POE、EVA、EPDM等三种热塑性弹性体基定形相变材料的储热及稳定性能明显优于目前报道的HDPE基定形相变材料的相应性能。
Optical resins with high refractive index used for encapsulant in light emitting diode(LED) is essential in avoiding stress shock and humidity corrosion, improving light extractionefficiency, reducing heat elimination and prolonging the service life of LED chip. Manyresearches showed that introducing sulfur element, by thioalcohol and thioether, into thechemical structure of polymer is regarded as one of the most effective methods to improverefractive index of optical resins.
However, there are some problems, such as high cost, poor stability or difficultprocessing, in optical resin with high refractive index up to now reported. The opticalmaterials with high refractive index, lower cost and better comprehensive performance areextremely needed to develop. Therefore, the main contents and results of this paper are asfollowing:
First, diglycidyl ether of thiodibenzenethiol (DGETDBT) and diglycidyl ether ofthiobis-phenol (DGETP) were synthesized using4,4’-thiodibenzenethiol,4,4'-thiobis-phenoland epichlorohydrin by two-step method. Their chemical structures were characterized withFTIR and1H NMR spectrometer. Using m-xylylenediamine (MXDA) andmethylhexahydrophthalic anhydride (MHHPA) as curing agent, curing behavior and thermalstability of DGETDBT and DGETP were studied by DSC and TGA and their lighttransmittance and refractive index were analyzed by UV–Vis scanning spectrophotometer andAbbe refractometer, compared with those performances of diglycidyl ether of bisphenol A(DGEBA).
The refractive indices of DGETDBT and DGETP were1.665and1.612.The refractiveindices of cured products with MXDA were1.698and1.645,1.628and1.595with MHHPA.It was all significantly higher than the corresponding values of DGEBA (1.604and1.568).The refractive index test showed that sulfur atoms in DGETDBT and DGETP contributed tothe obvious increasing of their refractive indices. The refractive indexes of cured productswere relevant to the refractive indices and proportion of epoxy prepolymer and curing agent.
The visible light transmittance of cured products of DGETDBT, DGETP and DGEBAwith MXDA and MHHPA were all exceeded85%, increasing in order. The transmittanceszero region of DGETDBT/MXDA and DGETDBT/MHHPA were200~370nm and200~390nm. It might protect people from UV radiation when these resins were used inencapsulant of light emitting diode (LED).
DGETDBT、DGETP和DGEBA three kinds of prepolymer had the same curing behavior and the cured products of these prepolymers and curing agent MXDA and MHHPA had agood thermal stability. The temperature at1%weight loss of these cured products allexceeded250℃，which is much higher than the normal usage temperature of LED.
The refractive index of DGETP (1.612) is higher than that of DGEBA (1.570) at thesame time it has the preferable thermal stability and acceptable price. Therefore DGETP canbe expected to be a kind of high rate of quantity and price encapsulant material for LED.
Second, thiol curing agent can possess high refractive index and high curing speed andimprove the toughness of cured product. Although thiophenol brings a high refractive index,the complex synthesis of thiophenol leads to the extremely high price. While aliphatic thiolcan be synthesized by thiourea of which the costing is acceptable.
O-benzenedimethanethiol(OBDMT) was synthesized using o-benzenedimethanechlorinevia thiourea-method in this paper. Its chemical structure was characterized with FTIR and1HNMR spectrometer. OBDMT was derived as a pale yellow or colorless crystal with arefractive index of about1.628. The refractive index of cured DGETP/OBDMT was1.654,the transmittance is near to85%and the glass transition temperature is close to28.7℃.Corresponding values for cured DGEBA/MHHPA were1.595,88%and64.9℃, respectively.The product of OBDMT has higer refractive index than the product of MHHPA.
Third, PETTA/PETTG and PETTA/OBDMT cured resin were prepared via an clickchemistry method in which pentaerythritol tetraacrylate (PETTA) respectively reated withpentaerythritol tetrathioglycolic (PETTG) and OBDMT. The thiol-ene addition reaction in thecuring course was mainly carried out by heat-curing or UV-curing.
PETTA/PETTG and PETTA/OBDMT cured resin both have low glass transitiontemperature. The refractive index of PETTA/OBDMT cured resin is1.597, but thermalstability and transmission of PETTA/OBDMT are lower than those of PETTA/PETTG curedresin. PETTA/PETTG cured resin have outstanding thermal stability (the temperature at1%mass loss thermal is324.2℃) and the higher transmission (over90%), which is on a par withthe silicone resin. The refractive index of PETTA/PETTG cured resin reached1.556，higherthan mostof silicone resin (the refractive index only1.410-1.530).
Fouth, the relationship between curing degree, curing time and refractive index ofDGETP/triethylene tetramine(TETA) mixture was studied by in-situ reaction method. Thereare the clearly exponential relation between the refractive index and curing degree or curingtime. The change of the refractive index and curing degree is bigger during its initial curingperiod, but those became smaller in the middle and later curing periods because molecular number and molecular volume had no evident changes. The result proved that the refractiveindex was mainly influenced by its molecular volume and the inherent molar refractivityaccording to the Lorentz–Lorenz equation.
The curing kinetics of DGETP/TETA cured product was studied by FTIR andnon-isothermal DSC．The reaction activation energy was52.6kJ·mol~(-1),56.3kJ·mol~(-1)and59.3kJ·mol~(-1), calculated by Kissinger equation, Ozawa equation and FTIR method,respectively. Three datas were conincident and could be validated with each other. the resultsfrom the non-isothermal curing kinetics in DSC showed that the reaction activation energy ofDGETP/MHHPA mixture was highest, followed by DGETP/TETA, and least byDGETP/OBDMT. The reaction order of DGETP/OBDMT was equal to that ofDGETP/TETA, different from that of DGETP/MHHPA. These results have been reflected bythe DSC curves.
The reaction activation energy, onset temperature and peak exothermic temperature ofDGEBA and DGETBBA have the high value, while corresponding values of DGEBATP andDGETDBT retained the lower value.
The end, the form-stable phase change materials (FSPCM) based on thermoplasticelastomers, such as POE, EVA and EPDM, were respectively preparated with paraffin,aimming at the heat problem of LED. The stabilities of FSPCM were measured via heatresistance test test, hot water bath test, temperature cycle test and differential scanningcalorimetry (DSC) test. The results showed that the heat storage and stable performances ofthree thermoplastic elastomer/wax FSPCMs were obvious better than those of HDPE/waxFSPCM.
采用4,4'-二巯基二苯硫醚和4,4'-二羟基二苯硫醚，通过二步法，分别合成了高折射率的二巯基二苯硫醚环氧预聚物（DGETDBT）和二羟基二苯硫醚环氧预聚物（DGETP）。通过傅里叶变换红外光谱仪（FTIR）和核磁共振仪的氢谱（1H NMR）表征合成产物的分子结构,用差示扫描量热仪（DSC）、热重分析仪（TGA）、热机械分析仪（TMA）、紫外可见光谱仪和阿贝折射仪分析环氧预聚物、环氧混合物及其固化物的光学性能、热性能和热稳定性，并与普通的双酚A环氧预聚物（DGEBA）的相应性能进行对比。分析表明，DGETDBT和DGETP的折射率分别为1.665和1.612，与间苯二甲胺（MXDA）固化反应得到的固化物折射率分别为1.698和1.645，与甲基六氢苯酐（MHHPA）固化反应得到的固化物折射率分别为1.628和1.595，高于DGEBA相应的1.570、1.604和1.568，表明硫原子对提高折射率有很大帮助。DGETDBT、DGETP和DGEBA与MXDA反应的固化物可见光透光率均超过85%，与MHHPA反应的固化物相应值超过88%。DGETDBT/MXDA和DGETDBT/MHHPA固化物透光率为零的区域为200~370nm和200~390nm。透光率为零的区域覆盖紫外线谱带有利于防止LED发出的紫外线泄露，保护人眼免受紫外线伤害。DGETDBT、DGETP和DGEBA固化时表现出同样的放热行为，与MXDA及MHHPA反应得到的固化物T1均超过250℃，明显高于LED的正常使用温度。DGETP价格适中，折射率为1.612，其他性能不低于DGEBA，有望成为LED的高效封装树脂。
硫醇类固化剂折射率高，固化速率快，且能提高固化产物的韧性。脂肪硫醇可通过硫脲法合成，合成过程比苯硫酚的合成过程简单。采用硫脲法合成邻苯二甲硫醇（OBDMT），FTIR和1H NMR表征合成产物的分子结构。OBDMT为无色晶体，折射率为1.628。DGETP/OBDMT固化物的折射率为1.654，透光性超过85%，玻璃化转变温度为28.7℃。DGETP/MHHPA固化物的折射率为1.595，透光性超过88%，玻璃化转变温度为64.9℃。对于同一种环氧树脂，OBDMT固化物比MHHPA固化物具有更高的折射率。
采用点击化学法，季戊四醇四丙烯酸酯（PETTA）分别与季戊四醇四巯基乙酸酯（PETTG）和OBDMT反应，通过热固化和紫外光固化两种工艺，制备PETTA/PETTG固化物和PETTA/OBDMT固化物。PETTA/OBDMT固化物的折射率为1.597，透光率基本超过85%，1%的热失重温度达237.8℃。PETTA/PETTG固化物的透光率最高达93%，1%的热失重温度达324.2℃，可以媲美有机硅封装树脂，其折射率为1.556，高于大部分有机硅封装树脂的1.410~1.530。
原位分析及拟合结果表明，折射率随着固化时间或者固化度呈明显的指数关系。在固化初始阶段，分子数目变化较快，体积收缩较大，因此折射率变化较快；在中后期阶段，分子数目变化不是特别明显，固化体系的体积收缩也较小，折射率增加不明显。这一结果与经典电磁学理论得到的Lorentz-Lorenz关系式相一致，即折射率受摩尔体积和摩尔折射率两者影响。
由FTIR法、Kissinger法和Ozawa法得到的DGETP/三乙烯四胺（TETA）混合物的固化表观活化能分别为52.6kJ·mol~(-1)、56.3kJ·mol~(-1)和59.3kJ·mol~(-1)，三个结果相近，可以相互验证。非等温DSC固化动力学研究表明，OBDMT固化DGETP的活化能最低，TETA的次之，MHHPA的最大。OBDMT固化DGETP的反应级数与TETA的相等，而MHHPA的反应级数则不相同，固化曲线上也表明这一点。DGEBA和DGETBBA的固化活化能、固化起点温度和峰值温度均较高，DGETP和DGETDBT的固化活化能、固化起点温度以及固化峰值温度均较低。
针对LED的发热问题，采用乙烯-辛烯共聚物（POE）、乙烯-醋酸乙烯酯共聚物（EVA）、三元乙丙橡胶（EPDM）等热塑性弹性体分别与石蜡一起制备定形相变材料。用耐热实验、耐热水实验和温度循环实验测试它们的稳定性，用DSC求取它们的热焓。结果表明，POE、EVA、EPDM等三种热塑性弹性体基定形相变材料的储热及稳定性能明显优于目前报道的HDPE基定形相变材料的相应性能。
Optical resins with high refractive index used for encapsulant in light emitting diode(LED) is essential in avoiding stress shock and humidity corrosion, improving light extractionefficiency, reducing heat elimination and prolonging the service life of LED chip. Manyresearches showed that introducing sulfur element, by thioalcohol and thioether, into thechemical structure of polymer is regarded as one of the most effective methods to improverefractive index of optical resins.
However, there are some problems, such as high cost, poor stability or difficultprocessing, in optical resin with high refractive index up to now reported. The opticalmaterials with high refractive index, lower cost and better comprehensive performance areextremely needed to develop. Therefore, the main contents and results of this paper are asfollowing:
First, diglycidyl ether of thiodibenzenethiol (DGETDBT) and diglycidyl ether ofthiobis-phenol (DGETP) were synthesized using4,4’-thiodibenzenethiol,4,4'-thiobis-phenoland epichlorohydrin by two-step method. Their chemical structures were characterized withFTIR and1H NMR spectrometer. Using m-xylylenediamine (MXDA) andmethylhexahydrophthalic anhydride (MHHPA) as curing agent, curing behavior and thermalstability of DGETDBT and DGETP were studied by DSC and TGA and their lighttransmittance and refractive index were analyzed by UV–Vis scanning spectrophotometer andAbbe refractometer, compared with those performances of diglycidyl ether of bisphenol A(DGEBA).
The refractive indices of DGETDBT and DGETP were1.665and1.612.The refractiveindices of cured products with MXDA were1.698and1.645,1.628and1.595with MHHPA.It was all significantly higher than the corresponding values of DGEBA (1.604and1.568).The refractive index test showed that sulfur atoms in DGETDBT and DGETP contributed tothe obvious increasing of their refractive indices. The refractive indexes of cured productswere relevant to the refractive indices and proportion of epoxy prepolymer and curing agent.
The visible light transmittance of cured products of DGETDBT, DGETP and DGEBAwith MXDA and MHHPA were all exceeded85%, increasing in order. The transmittanceszero region of DGETDBT/MXDA and DGETDBT/MHHPA were200~370nm and200~390nm. It might protect people from UV radiation when these resins were used inencapsulant of light emitting diode (LED).
DGETDBT、DGETP和DGEBA three kinds of prepolymer had the same curing behavior and the cured products of these prepolymers and curing agent MXDA and MHHPA had agood thermal stability. The temperature at1%weight loss of these cured products allexceeded250℃，which is much higher than the normal usage temperature of LED.
The refractive index of DGETP (1.612) is higher than that of DGEBA (1.570) at thesame time it has the preferable thermal stability and acceptable price. Therefore DGETP canbe expected to be a kind of high rate of quantity and price encapsulant material for LED.
Second, thiol curing agent can possess high refractive index and high curing speed andimprove the toughness of cured product. Although thiophenol brings a high refractive index,the complex synthesis of thiophenol leads to the extremely high price. While aliphatic thiolcan be synthesized by thiourea of which the costing is acceptable.
O-benzenedimethanethiol(OBDMT) was synthesized using o-benzenedimethanechlorinevia thiourea-method in this paper. Its chemical structure was characterized with FTIR and1HNMR spectrometer. OBDMT was derived as a pale yellow or colorless crystal with arefractive index of about1.628. The refractive index of cured DGETP/OBDMT was1.654,the transmittance is near to85%and the glass transition temperature is close to28.7℃.Corresponding values for cured DGEBA/MHHPA were1.595,88%and64.9℃, respectively.The product of OBDMT has higer refractive index than the product of MHHPA.
Third, PETTA/PETTG and PETTA/OBDMT cured resin were prepared via an clickchemistry method in which pentaerythritol tetraacrylate (PETTA) respectively reated withpentaerythritol tetrathioglycolic (PETTG) and OBDMT. The thiol-ene addition reaction in thecuring course was mainly carried out by heat-curing or UV-curing.
PETTA/PETTG and PETTA/OBDMT cured resin both have low glass transitiontemperature. The refractive index of PETTA/OBDMT cured resin is1.597, but thermalstability and transmission of PETTA/OBDMT are lower than those of PETTA/PETTG curedresin. PETTA/PETTG cured resin have outstanding thermal stability (the temperature at1%mass loss thermal is324.2℃) and the higher transmission (over90%), which is on a par withthe silicone resin. The refractive index of PETTA/PETTG cured resin reached1.556，higherthan mostof silicone resin (the refractive index only1.410-1.530).
Fouth, the relationship between curing degree, curing time and refractive index ofDGETP/triethylene tetramine(TETA) mixture was studied by in-situ reaction method. Thereare the clearly exponential relation between the refractive index and curing degree or curingtime. The change of the refractive index and curing degree is bigger during its initial curingperiod, but those became smaller in the middle and later curing periods because molecular number and molecular volume had no evident changes. The result proved that the refractiveindex was mainly influenced by its molecular volume and the inherent molar refractivityaccording to the Lorentz–Lorenz equation.
The curing kinetics of DGETP/TETA cured product was studied by FTIR andnon-isothermal DSC．The reaction activation energy was52.6kJ·mol~(-1),56.3kJ·mol~(-1)and59.3kJ·mol~(-1), calculated by Kissinger equation, Ozawa equation and FTIR method,respectively. Three datas were conincident and could be validated with each other. the resultsfrom the non-isothermal curing kinetics in DSC showed that the reaction activation energy ofDGETP/MHHPA mixture was highest, followed by DGETP/TETA, and least byDGETP/OBDMT. The reaction order of DGETP/OBDMT was equal to that ofDGETP/TETA, different from that of DGETP/MHHPA. These results have been reflected bythe DSC curves.
The reaction activation energy, onset temperature and peak exothermic temperature ofDGEBA and DGETBBA have the high value, while corresponding values of DGEBATP andDGETDBT retained the lower value.
The end, the form-stable phase change materials (FSPCM) based on thermoplasticelastomers, such as POE, EVA and EPDM, were respectively preparated with paraffin,aimming at the heat problem of LED. The stabilities of FSPCM were measured via heatresistance test test, hot water bath test, temperature cycle test and differential scanningcalorimetry (DSC) test. The results showed that the heat storage and stable performances ofthree thermoplastic elastomer/wax FSPCMs were obvious better than those of HDPE/waxFSPCM.
引文
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