High-Purity Alicyclic Epoxy Composition for Heat-Stable Transparency
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Solution Overview
Problem
Existing optical semiconductor devices face issues with yellowing of encapsulating resins due to heat, leading to reduced light intensity, and there is a need for resins with improved transparency, heat resistance, and curability.
Innovation Solution
The development of a high-purity alicyclic epoxy compound product with specific purity levels and low impurity content, produced through a method involving dehydration, epoxidation, and fractional distillation to enhance curability and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional curable epoxy resin compositions are used, then the resin provides basic encapsulation protection, but the resin yellows due to heat from optical semiconductor elements, reducing light intensity over time
Solution Approach 1:
The patent changes the chemical parameters of the epoxy resin by introducing alicyclic structures with specific molecular weights and epoxide group densities. This structural modification enables the resin to resist yellowing under heat while maintaining high transparency, resolving the contradiction between heat resistance and transparency
Solution Approach 2:
The patent creates a composite curable composition combining alicyclic epoxy compounds with specific curing agents and additives. This composite formulation achieves both excellent heat resistance and transparency, overcoming the limitations of conventional single-component epoxy resins
2Illumination intensity
If the purity of alicyclic epoxy compound is increased to improve transparency, then more complex purification processes are required, increasing manufacturing complexity
Solution Approach 1:
The patent performs preliminary purification actions during the synthesis stage by controlling reaction conditions and implementing initial filtration. This preliminary action removes most impurities before the main purification step, reducing the complexity of subsequent purification processes while achieving the required transparency
Solution Approach 2:
The patent extracts specific impurities (perhydrogenated products and isomers) from the alicyclic epoxy compound through selective purification steps. By targeting and removing only the critical impurities that affect transparency, the process achieves high purity without requiring excessively complex multi-stage purification
3Productivity
If perhydrogenated products and isomers are removed to improve curability, then more stringent purification requirements increase manufacturing difficulty
Solution Approach 1:
The patent changes the physical parameters (boiling points) of the target impurities through controlled hydrogenation degree. By adjusting the hydrogenation level, perhydrogenated products and isomers are created with distinct boiling points that allow for easy separation through simple distillation, improving curability without increasing purification difficulty
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting cured products exhibit excellent transparency and heat resistance, suitable for applications such as encapsulants, adhesives, and coating agents.
Implementation Method 1
introducing the reaction product above into a rectification column and fractionally distilling the reaction product under certain distillation conditions
Data Source
AI summary
Provided is an alicyclic epoxy compound product used in applications for forming a cured product excellent in transparency and heat resistance. An alicyclic epoxy compound product of the present disclosure has a purity of a compound represented by Formula (1) of 85 wt. % or greater; and a total content of a compound represented by Formula (a) and a compound represented by Formula (b) of 0.5 wt. % or less, where X represents a single bond or a linking group. The alicyclic epoxy compound product of the present disclosure can be produced through subjecting a compound represented by Formula (1″) to a dehydration reaction to obtain a compound represented by Formula (1′), and reacting the resulting compound represented by Formula (1′) with an organic peracid.