Alkali-Soluble Resin Composition for Heat-Resistant Cured Products
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Solution Overview
Problem
Conventional alkali-soluble resins suffer from heat-induced discoloration and have low refractive indexes, making them inadequate for optical applications requiring high refractive indexes.
Innovation Solution
An alkali-soluble resin with a specific structure and limited ammonium salt content, combined with an acid group-containing epoxy (meth)acrylate, is produced through a multi-step reaction process involving bifunctional epoxy compounds, unsaturated monobasic acids, and polybasic acid anhydrides to achieve high refractive index and heat discoloration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional alkali-soluble resins are used, then alkali developability and photocurability are excellent, but heat discoloration resistance is poor
Solution Approach 1:
The patent changes the chemical composition parameters by strictly limiting ammonium salt content to 0.06% or less and specifying precise molar ratios of reactants (bisphenol compound:epoxy compound = 1:(0.95-1.05), epoxy compound:unsaturated monobasic acid = 1:(0.95-1.05), reaction product:polybasic acid anhydride = 1:(0.95-1.05)). These parameter changes eliminate the discoloration issue while maintaining the desired alkali developability and photocurability.
2Reliability
If conventional alkali-soluble resins are used, then manufacturing is simple, but refractive index is low
Solution Approach 1:
The patent creates a composite resin system by reacting multiple components (bisphenol compound, epoxy compound, unsaturated monobasic acid, and polybasic acid anhydride) in specific molar ratios. This composite approach achieves high refractive index (suitable for optical applications) while maintaining manageable manufacturing through standardized multi-step synthesis procedures.
3Productivity
If ammonium salt content is increased to facilitate synthesis, then production efficiency improves, but heat discoloration resistance deteriorates
Solution Approach 1:
The patent extracts and eliminates the harmful ammonium salt component by strictly limiting its content to 0.06% or less of the total resin weight. This extraction approach removes the discoloration-causing element while preserving the essential catalytic function needed for synthesis, achieving both high reliability and acceptable production efficiency.
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 resin provides cured products with excellent heat discoloration resistance and high refractive indexes, suitable for various optical and electronic components.
Implementation Method 1
reacting a bisphenol compound with a bifunctional epoxy compound
Implementation Method 2
reacting a reaction product obtained in the step (a-1) with an unsaturated monobasic acid
Implementation Method 3
reacting a reaction product obtained in the step (a-2) with a polybasic acid anhydride
Data Source
AI summary
The present invention aims to provide an alkali-soluble resin and an alkali-soluble resin composition capable of providing a cured product having excellent heat discoloration resistance and a high refractive index, and to provide a production method capable of efficiently producing these. The present invention relates to an alkali-soluble resin having a structure represented by the following formula (1), the alkali-soluble resin containing an ammonium salt compound in an amount of 0.06% by mass or less relative to 100% by mass of the alkali-soluble resin,the formula (1) being as follows:wherein R1, R2, and R3 are the same as or different from each other and each represent a hydrogen atom or a C1-C6 hydrocarbon group; R4 represents a direct bond or a divalent organic group; R5, R6, R7, and R8 are the same as or different from each other and each represent a hydrogen atom or Y, with at least one of R5 to R3 being Y, where Y is a group represented by the following formula (2); R9 and R10 are the same as or different from each other and each represent a substituent; W represents a divalent organic group; X represents a direct bond or a divalent organic group; l represents the number of R9 and is an integer of 0 to 4; m represents the number of R10 and is an integer of 0 to 4; when multiple R9s are present, they are the same as or different from each other, and when multiple R10s are present, they are the same as or different from each other; and n is an integer of 1 or more,the formula (2) being as follows:wherein R11 represents a divalent organic group optionally containing a substituent.