Film type package of optical device

Abstract

Adhesive articles capable of forming encapsulation layers include a base layer that is optically clear and thermally stable for 1000 hours at a temperature of 130°C and a layer of a curable adhesive disposed on the base layer. The curable adhesive layer includes a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups such that upon heating to a temperature of 100°C to 150°C for 1 hour to 2 hours, the curable adhesive layer crosslinks to form an optically clear encapsulation layer. Methods of using these adhesive articles include disposing the adhesive article on a major surface of an optical article and curing the adhesive layer to form an encapsulated optical article.

Description

Summary of the Invention

[0001] This article discloses adhesive articles that can be used to form encapsulation layers, optical articles including adhesive articles, and methods for preparing optical articles.

[0002] This document discloses adhesive articles. In some embodiments, the adhesive article includes an optically transparent base layer that is thermally stable at 130°C for 1000 hours and a curable adhesive layer disposed on the base layer. The curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 to 2 hours, the curable adhesive layer crosslinks to form an optically transparent encapsulation layer.

[0003] This document also discloses optical articles including the aforementioned adhesive articles. In some embodiments, the optical article includes an optical device having a main surface and a cured adhesive article disposed on at least a portion of the main surface of the optical device and encapsulating that portion. The cured adhesive article includes the aforementioned curable adhesive article. The adhesive article has been disposed on the main surface of the optical device and cured. As described above, the curable adhesive article includes an optically transparent base layer that is thermally stable at 130°C for 1000 hours and a curable adhesive layer disposed on the base layer. The curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 hour to 2 hours, the adhesive layer crosslinks to form an optically transparent encapsulation layer.

[0004] In addition, this document discloses a method for preparing an optical article. In some embodiments, the method for preparing an optical article includes providing an optical device having a main surface, providing a curable adhesive article (wherein the curable adhesive article is as described above), disposing a curable adhesive layer of the curable adhesive article on at least a portion of the main surface of the optical device to form a laminated optical device, and applying heat of 100°C to 150°C to the laminated optical device for 1 hour to 2 hours to cure the curable adhesive layer, thereby forming an encapsulated optical device. Attached Figure Description

[0005] This application can be more fully understood by referring to the following detailed description of various embodiments of this disclosure in conjunction with the accompanying drawings.

[0006] Figure 1 This is a cross-sectional view of the product disclosed herein. Detailed Implementation

[0007] Various optical devices utilize LED displays. These displays offer a variety of desirable characteristics, including high grayscale, wide viewing angles, rich colors, and customizable screen shapes. LED displays use LEDs (light-emitting diodes). Developments in this technology include the emergence of mini-LED and micro-LED displays. The term "mini-LED" is used to describe the latest technology in TV displays that uses smaller LED chips to produce the same brightness as larger chips. This miniaturized design allows for finer control over lighting levels, making it ideal for both residential and commercial lighting applications. The term "micro-LED" refers to an emerging flat panel display technology composed of arrays of tiny LEDs that form individual pixel elements. Compared to widely used LCD technology, micro-LED displays offer better contrast, response time, and energy efficiency. They are also capable of high-speed modulation and have been proposed for chip-to-chip interconnect applications.

[0008] These LEDs are typically encapsulated to protect the LED components. This encapsulation usually involves a cured siloxane-based liquid, which allows the liquid to fill the gaps between the LED components.

[0009] There are many disadvantages to using curable liquid sealants. Liquids are messy and difficult to handle and apply to LED surfaces. Additionally, it is difficult to produce a uniform encapsulation layer when the liquid sealant cures. Therefore, a more convenient and consistent method for encapsulating LED surfaces is desired. A more convenient approach is to use an encapsulation layer that can be applied as a film-type article while still imparting the desired gap-filling properties of a liquid. Film-type articles are, as the name suggests, those articles that are film-type articles rather than liquids. An example of a film-type article is a tape. Tape articles are adhesive articles comprising a substrate or backing layer with an adhesive coating on the substrate or backing layer.

[0010] Using film-based products to encapsulate LED surfaces presents several challenges. Film-based products, such as liquid encapsulants, must be able to fill the gaps between LED elements. The adhesive layer must also bond firmly to the LED surface to maintain anchorage. The adhesive and substrate or backing layer must have suitable optical properties (such as optical transparency) and must maintain these optical properties over time and when exposed to the elevated temperatures experienced by the LED product during its assembly and use.

[0011] This disclosure describes a film-type article including a heat-stabilized film layer, on which a layer of curable adhesive is disposed. The adhesive article can be applied to the surface of an LED article and cured to encapsulate the LED surface. Optical articles having encapsulated LED surfaces are also disclosed, as well as methods for forming such optical articles.

[0012] As used herein, the term "adhesive" refers to a polymer composition that can be used to adhere two adhesives together. An example of an adhesive is an adhesive layer. These curable adhesive layers are applied in a curable state and then applied to a surface to form a permanent bond with the surface.

[0013] The term "(meth)acrylate" refers to the monomeric acrylate or methacrylate of an alcohol. Acrylates and methacrylate monomers or oligomers are collectively referred to herein as "(meth)acrylate". Materials referred to as "(meth)acrylate functionalized" are materials containing one or more (meth)acrylate groups. The term (meth)acrylate includes (meth)acryloyl compounds, such as acrylic acid and (meth)acrylic acid.

[0014] The term "epoxy-functional" refers to a compound containing at least one ethylene oxide ring. The term epoxy-functional includes epoxy-functional monomers, such as epoxy (meth)acrylates and epoxy resins.

[0015] The terms “room temperature” and “ambient temperature” are used interchangeably, referring to temperatures in the range of 20°C to 25°C.

[0016] As used in this article, the term "thermally stable" refers to a film whose optical properties do not change after 1000 hours at 130°C.

[0017] As used in this article, the term "adjacent" in the context of two floors means that the two floors are adjacent to each other and there is no intervening opening space between them. They may be in direct contact with each other (e.g., stacked together) or there may be an intervening floor.

[0018] As used herein, the terms “polymer” and “macromolecule” are consistent with their common usage in chemistry. Polymers and macromolecules are composed of many repeating subunits. As used herein, the term “macromolecule” is used to describe a group having multiple repeating units attached to a monomer. The term “polymer” is used to describe the material obtained by a polymerization reaction.

[0019] The term "alkyl" refers to a monovalent group that is an alkane group, where the alkane is a saturated hydrocarbon. Alkyl groups can be straight-chain, branched, cyclic, or combinations thereof, and typically have 1 to 20 carbon atoms. In some embodiments, the alkyl group contains 1 to 18, 1 to 12, 1 to 10, 1 to 8, 1 to 6, or 1 to 4 carbon atoms. Examples of alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, cyclohexyl, n-heptyl, n-octyl, and ethylhexyl.

[0020] The term "aryl" refers to a monovalent group consisting of an aromatic ring and a carbocyclic ring. An aryl group can have one to five rings attached to or fused with an aromatic ring. Other ring structures can be aromatic, non-aromatic, or combinations thereof. Examples of aryl groups include, but are not limited to, phenyl, biphenyl, terphenyl, anthryl, naphthyl, acenaphthenic, anthraquinone, phenanthryl, anthracenyl, pyrene, peryl, and fluorenyl.

[0021] The term "alkylene" refers to a divalent group that is a group of an alkane. Alkylenes can be straight-chain, branched, cyclic, or a combination thereof. Alkylenes typically have 1 to 20 carbon atoms. In some embodiments, alkylenes contain 1 to 18, 1 to 12, 1 to 10, 1 to 8, 1 to 6, or 1 to 4 carbon atoms. The center of the alkylene group can be on the same carbon atom (i.e., an alkylidene group) or on different carbon atoms.

[0022] The term "arylene" refers to a divalent group consisting of a carbocyclic ring and an aromatic ring. This group has one to five rings, either linked, fused, or in combination thereof. The other rings may be aromatic, non-aromatic, or combinations thereof. In some embodiments, the arylene group has up to five rings, up to four rings, up to three rings, up to two rings, or one aromatic ring. For example, the arylene group may be phenylene.

[0023] The term "heteroalkylene" refers to a divalent group comprising at least two alkylene groups linked by a thio group, an oxygen group, or -NR-, wherein R is an alkyl group. Heteroalkylenes can be straight-chain, branched, cyclic, substituted with alkyl groups, or combinations thereof. Some heteroalkylenes are polyoxyalkylenes with oxygen as the heteroatom, such as, for example, -CH2CH2(OCH2CH2). n OCH2CH2-.

[0024] The terms “radical polymerizable” and “olefinic unsaturated” are used interchangeably and refer to reactive groups containing carbon-carbon double bonds capable of polymerization via a radical polymerization mechanism.

[0025] Unless otherwise specified, the terms "optically transparent" and "visible light transmittance" are used interchangeably and refer to articles, films, or adhesives having high transmittance over at least a portion of the visible light spectrum (about 400 nm to about 700 nm). Typically, optically transparent articles have at least 90% visible light transmittance and less than 10% haze.

[0026] Unless otherwise specified, "optically transparent" means an adhesive or article that has high transmittance and exhibits low haze (typically less than about 5%, or even less than about 2%) over at least a portion of the visible light spectrum (about 400 nm to about 700 nm). In some embodiments, the optically transparent article exhibits haze of less than 1% or even 0.5% at a thickness of 50 micrometers. Typically, the optically transparent article has at least 95%, and often higher, such as 97%, 98%, or even 99% or higher, of visible light transmittance.

[0027] This document discloses adhesive articles capable of encapsulating optical devices. In some embodiments, the adhesive article comprises an optically transparent substrate layer that is thermally stable at 130°C for 1000 hours and a curable adhesive layer disposed on the substrate layer. The curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 to 2 hours, the curable adhesive layer crosslinks to form an optically transparent encapsulation layer.

[0028] The adhesive article includes a base layer. This base layer is optically transparent and thermally stable. Typically, the base layer is a polymer film. In many embodiments, the base layer includes an optical film. An optical film is well understood in the field of optics as a film that produces an optical effect. In many embodiments, the optical film is optically transparent / optically clear, and the optical effect is high visible light transmittance and low haze. Other films with other optical effects may also be used, such as light-diffusing films, for example, for diffusing or softening light passing through them.

[0029] In addition to the desired optical properties, the substrate layer is also thermally stable. In this context, thermal stability means that the substrate layer does not change its optical properties after being heated to 130°C for 1000 hours. Typically, the substrate layer is also dimensionally stable, meaning that it does not shrink or expand during the preparation or use of the adhesive article.

[0030] A variety of optical films are suitable for use in the adhesive articles of this disclosure. Examples of suitable substrate layers include: polyolefins, such as polyethylene, polypropylene, and blends thereof; polyesters, such as PET (polyethylene terephthalate); poly(meth)acrylates, such as PMMA (polymethyl methacrylate); polyurethanes; polycarbonates; polyimides, such as CPI (colorless polyimide); and combinations thereof.

[0031] The adhesive article also includes a curable adhesive layer. The curable adhesive layer comprises a poly(meth)acrylate-based matrix. The poly(meth)acrylate-based matrix is ​​formed by photopolymerization of a reaction mixture comprising: at least one first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group having 4 to 20 carbon atoms; at least one second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; at least one third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene or heteroaryl group; at least one fourth (meth)acrylate monomer comprising an acid-functionalized (meth)acrylate monomer; at least one fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and at least one photoinitiator.

[0032] Typically, a reaction mixture is prepared and at least partially polymerized to form a coatable slurry. This coatable slurry is suitable for application onto a substrate to form a curable adhesive article.

[0033] The reaction mixture contains a first (meth)acrylate monomer of general formula 1: CH2=CR 1 -C(O)-OR 2 Formula 1 Where R 1 It is a hydrogen or methyl group, -C(O)- is a carbonyl group C=O, and R 2 It is an alkyl group containing 4 to 20 carbon atoms. Various alkyl methacrylate monomers are suitable.

[0034] Suitable (meth)acrylate alkyl ester monomers include, but are not limited to, those selected from esters of acrylic acid or methacrylic acid with non-tertiary alkyl alcohols (such as 1-butanol, 1-pentanol, 2-pentanol, 3-pentanol, 2-methyl-1-butanol, 1-methyl-1-butanol, 1-methyl-1-pentanol, 2-methyl-1-pentanol, 3-methyl-1-pentanol, 2-ethyl-1-butanol, 2-ethyl-1-hexanol, 3,5,5-trimethyl-1-hexanol, 3-heptanol, 2-octanol, 1-decanol, 1-dodecanol, etc.), and mixtures thereof. Such monomeric acrylates or methacrylates are known in the art and are commercially available. In some embodiments, the first (meth)acrylate monomer comprises an alkyl group containing 8 to 18 carbon atoms. Examples of particularly suitable alkyl acrylate monomers are isooctyl acrylate, 2-ethylhexyl acrylate, lauryl acrylate, isobutyl acrylate, dodecyl acrylate, and mixtures thereof.

[0035] In some embodiments, the first monomer of the reaction mixture comprises a mixture of monomers. Examples of such monomer mixtures include a mixture comprising at least two alkyl (meth)acrylate monomers having at least eight carbon atoms and at least one branched alkyl (meth)acrylate monomer having at least nine carbon atoms.

[0036] The reaction mixture contains a second (meth)acrylate monomer of general formula 2: CH2=CR 1 -C(O)-OR 3 Formula 2 Where R 1 It is a hydrogen or methyl group, -C(O)- is a carbonyl group C=O, and R 3 It is a hydroxyl-functionalized alkyl group. Typically, a hydroxyl-functionalized alkyl group contains a single hydroxyl group, but it can contain more than one hydroxyl group. A hydroxyl-functionalized alkyl group can have a terminal hydroxyl group, such that R... 3 It has the general formula: -(CH2) a -OH, where a is a 2 or larger integer, or it may have a hydroxyl group positioned along the alkyl chain. Particularly suitable (meth)acrylate monomers with hydroxyl-functionalized alkyl groups are 2-HPA (2-hydroxypropyl acrylate) having the general formula 2A: CH2=CH-C(O)-O-CH2-CH(OH)-CH3 Formula 2A The reaction mixture contains a third (meth)acrylate monomer of general formula 3: CH2=CR 1 -C(O)-OR 4 Formula 3 Where R 1 It is a hydrogen or methyl group, -C(O)- is a carbonyl group C=O, and R 4 It is a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups. Typically, one or more heteroatoms are oxygen atoms. In some embodiments, R... 4 It has the following general formula structure: -(R 5 -O) c -R 6 Where c is an integer of 1 or greater; R 5 It is an alkylene group having 1 to 5 carbon atoms or an arylene group having 6 to 10 carbon atoms; and R 6 It is an alkyl group having 1 to 5 carbon atoms or an aryl group having 6 to 10 carbon atoms. In some embodiments, R 5 It is an alkylene group; and R6 It is an aryl group. A particularly suitable third (meth)acrylate monomer is PHEA (phenoxyethyl acrylate), in which R 5 It is an ethylene group; and R 6 It is a phenyl group.

[0037] The reaction mixture contains a fourth (meth)acrylate monomer of general formula 4: CH2=CR 1 -C(O)-OR 7 Formula 4 Where R 1 It is a hydrogen or methyl group, and R 7 It is an acidic group (-C(O)OH), where C(O) is a carbonyl group C=O, or the general formula -(CH2). a -OC(O)OH is an acid-functionalized alkyl group, where a is an integer of 2 or greater. Particularly suitable fourth monomers are acrylic acid and methacrylic acid.

[0038] The reaction mixture contains the fifth (meth)acrylate monomer of general formula 5: CH2=CR 1 -C(O)-OR 8 Formula 5 Where R 1 It is a hydrogen or methyl group, and R 8 It has the general formula -(CH2). d -A is an epoxy functional group, where d is an integer of 1 or greater, and A is an ethylene oxide ring. Typically, d is 3 or less. Particularly suitable fifth monomers are those where d is 1, glycidyl acrylate (GA) and glycidyl methacrylate (GMA).

[0039] The reaction mixture also contains at least one photoinitiator. A photoinitiator is an initiator activated by light (typically ultraviolet (UV) light), but other light sources can be used depending on the appropriate selection of the initiator (such as visible light initiators, infrared light initiators, etc.) to form free radicals and initiate free radical polymerization. Typically, UV photoinitiators are used as initiators. Photoinitiators are well known to those skilled in the art of (meth)acrylate polymerization. Examples of suitable free radical photoinitiators include IRGACURE 4265, IRGACURE 184, IRGACURE 651, IRGACURE 1173, IRGACURE 819, IRGACURE TPO, and IRGACURE TPO-L, commercially available from BASF, Charlotte, NC, North Carolina.

[0040] The reaction mixture containing the above monomers can have various compositions. In some embodiments, the reaction mixture forming the curable adhesive layer comprises: From 50 to 75 parts by weight of at least one first (meth)acrylate monomer, the first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms; From 10 to 20 parts by weight of at least one second (meth)acrylate monomer, the second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; From 10 parts by weight to 35 parts by weight of at least one third (meth)acrylate monomer, the third (meth)acrylate monomer comprising (meth)acrylate having a heteroalkylene or heteroaryl group; From 1 part by weight to 4 parts by weight of at least one fourth (meth)acrylate monomer, the fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; From 1 part to 5 parts by weight of at least one fifth (meth)acrylate monomer, the fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator, in amounts ranging from 0.01 parts by weight to 1.0 parts by weight.

[0041] In addition to a poly(meth)acrylate-based matrix, the curable adhesive layer may also have additional optional additives, provided that the additives do not adversely affect the optical or thermal stability properties of the curable adhesive layer. Particularly suitable additives are antioxidants. Examples of suitable antioxidants include hindered phenolic antioxidants, alkyl-aryl phosphites, or combinations thereof. Examples of hindered phenolic antioxidants include ADK STAB AO-80 and ADK STAB AO-20 from ADEKA, Hasbrouck Heights, NJ, or IRGANOX 1010 from BASF. Examples of alkyl-aryl phosphite antioxidants include ADK STAB PEP-36 and ADK STAB PEP-8 from ADEKA, Hasbrouck Heights, NJ, and IRGANOX 168 from BASF. In some embodiments, the curable adhesive layer also contains 0.01 to 0.2 parts by weight of at least one antioxidant.

[0042] As described above, the adhesive article of this disclosure has a number of desirable characteristics. The substrate is optically transparent and thermally stable, meaning that when aged at 130°C for 1000 hours, the substrate retains its optical transparency, such as through transmittance, haze, and b. The measurements were taken. Additionally, the curable adhesive layer is thermally stable during curing to form the encapsulation layer, maintaining optical transparency, such as through transmittance, haze, and b, after aging at 130°C for 1000 hours. The measured values ​​indicate that the cured adhesive product exhibits optical transparency and retains it after aging at 130°C for 1000 hours, as measured by transmittance, haze, and b. The measurements were taken.

[0043] This disclosure also describes optical articles. Optical articles include optical devices having a main surface and cured adhesive articles disposed on at least a portion of the main surface of the optical device and encapsulating that portion. Cured adhesive articles include curable adhesive articles disposed on the main surface of the optical device and cured. Curable adhesive articles have been described above and include a substrate layer and a curable adhesive layer disposed on the substrate layer. The substrate layer is optically transparent and thermally stable at 130°C for 1000 hours. The curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 hour to 2 hours, the adhesive layer crosslinks to form an optically transparent encapsulation layer.

[0044] Various optical devices can be used to form the optical articles disclosed herein. Examples of suitable optical devices having a main surface include LEDs, mini LEDs, or micro LEDs.

[0045] Optical articles also include cured adhesive articles, which are curable adhesive articles that have been cured on at least a portion of the main surface of the optical device. Curable adhesive articles are described in detail above and include a base layer, which typically comprises an optical film and a curable adhesive layer.

[0046] As described above, the curable adhesive layer comprises a poly(meth)acrylate-based matrix formed by photopolymerization of a reaction mixture, the reaction mixture comprising: at least one first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group having 4 to 20 carbon atoms; at least one second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; at least one third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene group, a heteroaryl group, or a combination of heteroalkylene and heteroaryl groups; at least one fourth (meth)acrylate monomer comprising an acid-functionalized (meth)acrylate monomer; at least one fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and at least one photoinitiator. Each of these components is described in detail above.

[0047] The present invention also discloses a method for preparing an optical article. The method includes providing an optical device having a main surface, providing a curable adhesive article comprising a substrate layer and a curable adhesive layer, disposing the curable adhesive layer of the curable adhesive article on at least a portion of the main surface of the optical device to form a laminated optical device, and applying heat of 100°C to 150°C to the laminated optical device for 1 hour to 2 hours to cure the curable adhesive layer, thereby forming an encapsulated optical device.

[0048] Various optical devices can be used in the methods for forming the optical articles of this disclosure. Examples of suitable optical devices having a main surface include LEDs, mini LEDs, or micro LEDs.

[0049] As described above, the curable adhesive article includes a base layer and a curable adhesive layer disposed on the base layer. The base layer is optically transparent and thermally stable at 130°C for 1000 hours, and is typically an optical film. The curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 to 2 hours, the adhesive layer crosslinks to form an optically transparent encapsulation layer.

[0050] As described above, the curable adhesive layer comprises a poly(meth)acrylate-based matrix formed by photopolymerization of a reaction mixture, the reaction mixture comprising: at least one first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group having 4 to 20 carbon atoms; at least one second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; at least one third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene group, a heteroaryl group, or a combination of heteroalkylene and heteroaryl groups; at least one fourth (meth)acrylate monomer comprising an acid-functionalized (meth)acrylate monomer; at least one fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and at least one photoinitiator. Each of these components is described in detail above.

[0051] exist Figure 1 Examples of optical articles described in this disclosure are described in the document. Figure 1 A cross-sectional view of article 100 is shown. Article 100 shows an encapsulated optical article. The optical article includes a substrate 120 and an LED 130. The optical article is encapsulated by a cured two-layer adhesive article 110 having a film layer 111 and an adhesive layer 112. Each of these components is as described above.

[0052] Example

[0053] These embodiments are for illustrative purposes only and are not intended to limit the scope of the appended claims. Unless otherwise specified, all parts, percentages, ratios, etc., in the embodiments and the remainder of the specification are by weight. The following abbreviations are used: mm = millimeter; nm = nanometer; s = second; h = hour; mW = milliwatt; RH = relative humidity; kPa = kilopascal.

[0054]

[0055] Test methods

[0056] Aging test

[0057] The sample was laminated between two glass plates, and air bubbles were removed using an autoclave process. The sample was then aged in a 130°C oven. Before and after aging, Hazeguard (for haze and transmittance testing) and Konica Minolta 3700d (for b) were used. (Test) to test optical performance.

[0058] Rheological testing

[0059] The rheological properties of the samples before and after curing were tested using a DHR30 from TA Instruments.

[0060] On-chip testing

[0061] The sample was laminated onto a mini-LED board and then covered with optical glass. The mini-LED board with the adhesive sample was placed in an aging chamber at 105°C with the mini-LED illumination kept on (current constant of 0.05A) for 1000 hours, and then the brightness of the mini-LED after aging was checked compared with the initial value.

[0062] Examples Ex1 to Ex4

[0063] Sample preparation

[0064] Step 1: Preparation of slurry

[0065] A series of slurries were prepared by mixing the monomers and initiators shown in Table 1. All amounts are by weight. The mixtures were purged with N2. The mixtures were then exposed to 60 mW 365 nm UV light for 30 s.

[0066]

[0067] Step 2: Preparation of adhesive film

[0068] The additional components shown in Table 2 were mixed with the slurry shown in Table 1 by weight, and the mixture was subjected to vacuum treatment. The resulting adhesive mixture was coated between two release liner pads with a gap of 200 micrometers and then cured under 365nm LED light, wherein Ex1, Ex2-1, Ex3-1, and Ex4-1 were cured with UV settings of 3mW 120s and 9mW 80s, while Ex2-2, Ex3-2, and Ex4-2 were cured with UV settings of 2mW 120s and 9mW 80s to form an adhesive layer.

[0069]

[0070] Step 3: Application and Curing Method

[0071] For aging tests, an adhesive layer was laminated between two optical glass plates, and the laminate was cured in a 150°C oven for 2 hours. Initial and aged optical properties (T, H, b) were then tested (aging conditions: 130°C for 1000 hours and 85 / 85 (85°C / 85 RH) for 1000 hours). ).

[0072] For rheological testing of uncured samples, five layers of each adhesive were stacked to prepare a 1 mm thick sample, which was then stamped to an 8 mm diameter, and its rheological properties were tested using a TA DHR3 rheometer. For rheological testing of cured samples, the uncured adhesive sample was placed in a 150°C oven for 2 hours to cure, and then the same steps used to prepare the uncured sample were followed to prepare the stamped sample.

[0073] Step 4: Testing and Results

[0074] Aging performance

[0075] The optical performance of samples Ex1-Ex4 was tested, and after 1000 hours of aging, the optical performance was retested. Ex1 (without HPA version) showed very high haze and high b. Ex2 (without PHEA version) shows high b This indicates that both hydroxy acrylates (such as HPA) and PHEA are required for this application. The data is shown in Table 3 below.

[0076]

[0077] Rheological properties

[0078] Rheological properties were tested, and the storage modulus G' and tanδ (tanD) (G'' / G') are shown in Table 4. A high tanD before curing (preferably >0.5) is desired to provide good gap-filling capability to cover the height of the mini-LED chip. A high G' after curing is also desired to provide sufficient bond strength and stability at both room temperature and high temperature. Both room temperature (25°C) and high temperature (95°C) G' after curing are expected to be greater than 100 kPa.

[0079]

[0080] Examples Ex5 to Ex7

[0081] Sample preparation

[0082] Step 1: Slurry Preparation

[0083] Two slurries were prepared by mixing the monomers and initiators shown in Table 5. All amounts are by weight. The mixture was purged with N2. The mixture was then exposed to 60 mW 365 nm UV light for 30 s.

[0084]

[0085] Step 2: Preparation of adhesive film

[0086] The additional components shown in Table 6 were mixed with the slurry shown in Table 5, and the mixture was subjected to vacuum treatment. The resulting adhesive mixture was coated between two release liner pads with a gap of 250 micrometers, and then cured under 365nm LED light with UV settings of 3mW for 120s and 9mW for 80s to form an adhesive layer.

[0087]

[0088] Step 3: Application and Curing Method

[0089] An adhesive layer was applied to the mini-LED board, and then an optical glass layer was laminated to the other surface of the adhesive. The laminate was placed in a 150°C oven for 2 hours to cure. The two mini-LED boards were then placed in a 105°C oven for 1000 hours of aging, during which time the mini-LED lighting was kept on (constant current of 0.05A).

[0090] Step 4: Testing and Results

[0091] Adhesive samples Ex5, Ex6, and Ex7 were laminated onto regions 1, 2, and 3, respectively, while region 4 was left unlaminated as a blank reference.

[0092] The brightness of each area of ​​the mini-LED board was tested before and after aging, and the percentage change is recorded in Table 7. Note that the brightness of area 3 (sample Ex7) decreased, while Ex5 and Ex6 both performed well.

[0093]

[0094] Lamination on substrate in Example Ex6

[0095] Sample preparation

[0096] Step 1: Preparation of slurry

[0097] Prepare slurry 5 as described above (shown in Table 5).

[0098] Step 2: Preparation of adhesive film

[0099] The adhesive mixture Ex6 was prepared as described in Table 6. The adhesive mixture was coated between a release liner and a PC film with a gap of 250 micrometers, and then cured under 365nm LED light with UV settings of 3mW for 120s and 9mW for 80s to form an adhesive layer.

[0100] Step 3: Application and Curing Method

[0101] Glass beads (150 micrometers in diameter) were laid onto a glass substrate, and then adhesive was laminated onto the glass substrate with the PC surface facing outwards. The laminate was placed in an oven at 150°C for 2 hours to cure. The coverage of the glass beads was observed.

[0102] Step 4: Testing and Results

[0103] Observe the air bubbles in the cured laminate prepared above. No air bubbles were observed after lamination and curing, indicating that the 250-micrometer-thick adhesive can effectively cover the 150-micrometer-thick glass beads.

Claims

1. An adhesive article, said adhesive article comprising: The substrate layer is optically transparent and thermally stable at 130°C for 1000 hours; and A curable adhesive layer disposed on the substrate layer, wherein the curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 to 2 hours, the curable adhesive layer crosslinks to form an optically transparent encapsulation layer.

2. The adhesive article of claim 1, wherein the curable adhesive layer comprises a poly(meth)acrylate-based matrix formed by photopolymerization of a reaction mixture, said reaction mixture comprising: At least one first (meth)acrylate monomer, the first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms; At least one second (meth)acrylate monomer, the second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; At least one third (meth)acrylate monomer, said third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups; At least one fourth (meth)acrylate monomer, said fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; At least one fifth (meth)acrylate monomer, said fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator.

3. The adhesive article according to claim 1, wherein the base layer comprises an optical film.

4. The adhesive article according to claim 3, wherein the optical film is optically transparent or diffuse.

5. The adhesive article of claim 1, wherein the curable adhesive layer is thermally stable when cured to form an encapsulation layer and retains optical transparency, such as by means of transmittance, haze, and b, after aging at 130°C for 1000 hours. The measurements were taken.

6. The adhesive article of claim 2, wherein the first monomer of the reaction mixture comprises a mixture of monomers.

7. The adhesive article of claim 6, wherein the mixture of monomers of the first monomer comprises: At least two alkyl (meth)acrylate monomers having at least eight carbon atoms; and At least one branched (meth)acrylate alkyl ester monomer having at least 9 carbon atoms.

8. The adhesive article of claim 6, wherein the reaction mixture forming the curable adhesive layer comprises: From 50 to 75 parts by weight of at least one first (meth)acrylate monomer, wherein the first (meth)acrylate monomer comprises an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms. From 10 to 20 parts by weight of at least one second (meth)acrylate monomer, wherein the second (meth)acrylate monomer comprises a (meth)acrylate having a hydroxyl-functionalized alkyl group; From 10 to 35 parts by weight of at least one third (meth)acrylate monomer, said third (meth)acrylate monomer comprising (meth)acrylate having a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups. From 1 part by weight to 4 parts by weight of at least one fourth (meth)acrylate monomer, said fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; From 1 part by weight to 5 parts by weight of at least one fifth (meth)acrylate monomer, said fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator, in amounts ranging from 0.01 parts by weight to 1.0 parts by weight.

9. The adhesive article of claim 1, wherein the curable adhesive layer further comprises at least one antioxidant.

10. An optical article, the optical article comprising: Optical devices with a main surface; as well as A cured adhesive article, said cured adhesive article being disposed on at least a portion of the main surface of the optical device and encapsulating that portion, wherein said cured adhesive article includes a curable adhesive article that has been disposed on the main surface of the optical device and cured, said curable adhesive article comprising: The substrate layer is optically transparent and thermally stable at 130°C for 1000 hours; and A curable adhesive layer disposed on the substrate layer, wherein the curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 to 2 hours, the adhesive layer crosslinks to form an optically transparent encapsulation layer.

11. The optical article of claim 10, wherein the optical device having a main surface comprises an LED, a mini LED, or a micro LED.

12. The optical article of claim 10, wherein the curable adhesive layer comprises a poly(meth)acrylate-based matrix formed by photopolymerization of a reaction mixture, said reaction mixture comprising: At least one first (meth)acrylate monomer, the first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms; At least one second (meth)acrylate monomer, the second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; At least one third (meth)acrylate monomer, said third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups; At least one fourth (meth)acrylate monomer, said fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; At least one fifth (meth)acrylate monomer, said fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator.

13. The optical article of claim 10, wherein the substrate layer comprises an optical film.

14. The optical article of claim 10, wherein the curable adhesive layer is thermally stable when cured to form an encapsulation layer and maintains optical transparency, as measured by transmittance, haze, and b, when aged at 130°C for 1000 hours.

15. The optical article of claim 10, wherein the reaction mixture forming the curable adhesive layer comprises: From 50 to 75 parts by weight of at least one first (meth)acrylate monomer, wherein the first (meth)acrylate monomer comprises an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms. From 10 to 20 parts by weight of at least one second (meth)acrylate monomer, the second (meth)acrylate monomer comprising a (meth)acrylate having an alkyl group comprising a non-acidic and non-basic polar group. From 10 to 35 parts by weight of at least one third (meth)acrylate monomer, said third (meth)acrylate monomer comprising (meth)acrylate having a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups. From 1 part by weight to 4 parts by weight of at least one fourth (meth)acrylate monomer, said fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; From 1 part by weight to 5 parts by weight of at least one fifth (meth)acrylate monomer, said fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator, in amounts ranging from 0.01 parts by weight to 1.0 parts by weight.

16. A method for manufacturing an optical article, the method comprising: Provide an optical device with a main surface; Provides a curable adhesive product, said curable adhesive product comprising: A substrate layer that is optically transparent and thermally stable at 130°C for 1000 hours; and A curable adhesive layer disposed on the substrate layer, wherein the curable adhesive layer comprises a poly(meth)acrylate-based matrix containing acid functional groups and epoxy functional groups, such that when heated to a temperature of 100°C to 150°C for 1 to 2 hours, the adhesive layer crosslinks to form an optically transparent encapsulation layer. The curable adhesive layer of the curable adhesive article is disposed on at least a portion of the main surface of the optical device to form a laminated optical device; and Heat of 100°C to 150°C is applied to the laminated optical device for 1 to 2 hours to cure the curable adhesive layer, thereby forming an encapsulated optical device.

17. The method of claim 16, wherein the optical device having a main surface comprises an LED, a mini LED, or a micro LED.

18. The method of claim 16, wherein the curable adhesive layer comprises a poly(meth)acrylate-based matrix formed by photopolymerization of the reaction mixture, the reaction mixture comprising: At least one first (meth)acrylate monomer, the first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms; At least one second (meth)acrylate monomer, the second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; At least one third (meth)acrylate monomer, said third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups; At least one fourth (meth)acrylate monomer, said fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; At least one fifth (meth)acrylate monomer, said fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator.

19. The method of claim 16, wherein the substrate layer comprises an optical film.

20. The method of claim 16, wherein the curable adhesive layer is thermally stable when cured to form an encapsulation layer and retains optical transparency, such as by transmittance, haze, and b, after aging at 130°C for 1000 hours. The measurements were taken.

21. The method of claim 16, wherein providing the curable adhesive article comprises: Provide a base; A poly(meth)acrylate matrix precursor reaction mixture was prepared, the poly(meth)acrylate matrix precursor reaction mixture comprising: At least one first (meth)acrylate monomer, the first (meth)acrylate monomer comprising an alkyl (meth)acrylate having an alkyl group comprising 4 to 20 carbon atoms; At least one second (meth)acrylate monomer, the second (meth)acrylate monomer comprising a (meth)acrylate having a hydroxyl-functionalized alkyl group; At least one third (meth)acrylate monomer, said third (meth)acrylate monomer comprising a (meth)acrylate having a heteroalkylene group, a heteroarylene group, or a combination of heteroalkylene and heteroarylene groups; At least one fourth (meth)acrylate monomer, said fourth (meth)acrylate monomer comprising an acid-functional (meth)acrylate monomer; At least one fifth (meth)acrylate monomer, said fifth (meth)acrylate monomer comprising an epoxy-functionalized (meth)acrylate monomer; and At least one photoinitiator; The poly(meth)acrylate matrix precursor reaction mixture is photopolymerized to form a curable adhesive composition; Add additional photoinitiator; and The curable adhesive composition is disposed on the substrate to form the curable adhesive article.

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