Gradient Composite Material and Method of Manufacturing the Same

• US 20120112219A1
• Filed: 11/04/2010
• Published: 05/10/2012
• Est. Priority Date: 11/04/2010
• Status: Active Grant

• Current Assignee: Industrial Technology Research Institute
• Original Assignee: Industrial Technology Research Institute
• Inventors: Jang, Guang-Way, Pu, Ying-Chih, Yang, Yin-Ju, Chang, Chih-Fen, Wong, Chang-Ming
• Granted Patent: US 8,368,106 B2
• Time in Patent Office: Days
• US Class Current: 257/98
• CPC Class Codes: B82Y 20/00 Nanooptics, e.g. quantum optics or photonic crystals
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C08J 2300/00 Characterised by the use of unspecified polymers
• CPC Class Codes: C08J 5/005 Reinforced macromolecular compounds with nanosized materials, e.g. nanoparticles, nanofibres, nanotubes, nanowires, nanorods or nanolayered materials
• CPC Class Codes: H01L 2933/0041 relating to wavelength conversion elements
• CPC Class Codes: H01L 2933/005 relating to encapsulations
• CPC Class Codes: H01L 33/508 having a non-uniform spatial arrangement or non-uniform concentration, e.g. patterned wavelength conversion layer, wavelength conversion layer with a concentration gradient of the wavelength conversion material

Abstract

Method of manufacturing gradient composite material comprises steps of providing plural surface modified inorganic nanoparticles with functional groups or oligomers with functional groups; transferring the surface modified inorganic nanoparticles or oligomers with functional groups into an organic matrix to form a mixture; performing a photo polymerization step or a thermo-polymerization step for polymerizing and generating a gradient distribution of the surface modified inorganic nanoparticles or oligomers with functional groups in the mixture; and curing the mixture to solidify the organic matrix and form a structure with gradient composite, wherein the organic matrix is transferred into an organic polymer after curing.

Claims

1. A method of manufacturing gradient composite material, comprising:

providing plural surface modified inorganic nanoparticles with functional groups or oligomers with functional groups, and the surface modified inorganic nanoparticles comprising at least one kind of metal oxide nanoparticles, metal nanoparticles and semiconductor nanoparticles;

transferring the surface modified inorganic metal oxide nanoparticles or oligomers with functional groups into an organic matrix to form a mixture;

performing a gradient step, comprising a photo-polymerization step or a thermo-polymerization step for polymerizing and generating a gradient distribution of the surface modified inorganic metal oxide nanoparticles or oligomers with functional groups in the mixture; and

curing the mixture to solidify the organic matrix and form a structure with gradient composite, wherein the organic matrix is transferred into an organic polymer after curing.

2. The method according to claim 1, wherein the metal oxide nanoparticles are selected from the group consisting of titanium dioxide (TiO₂), zirconium oxide (ZrO₂), silicon dioxide (SiO₂), zinc oxide (ZnO), cerium oxide (CeO₂), cadmium oxide (CdO), aluminum oxide (Al₂O₃), ferric oxide (Fe₂O₃), tantalum(V) oxide (Ta₂O₅), copper(I) oxide (Cu₂O), indium oxide (In₂O₃), lanthanum(III) oxide (La₂O₃), vanadium(V) oxide (V₂O₅), molybdenum(VI) oxide (MoO₃) and tungsten(VI) oxide (WO₃);

the inorganic metal nanoparticles selected from the group consisting of Cu, Ag, Au, Ni, Fe and Co; and

the inorganic semiconductor nanoparticles comprising either plural core-shell nanoparticles having metal oxide shell or plural core solely, and the cores selected from the group consisting of CdSe, Cd_xZn_1-xSe (0.01 x 0.99), Cd_xZn_1-xS (0.01 x 0.99), Cd_xZn_1-xS_ySe_1-y (0.01 x 0.99 and 0.01 y 0.99), CdSe—

ZnS, CdSe—

CdTe, CdTe, CdS, CdS—

ZnS, CdSe—

CdTe—

ZnSe, ZnS, ZnTe, PbS, PbSe, PbTe, ZnO, and Si.

3. The method according to claim 1, wherein the step of providing the surface modified inorganic nanoparticles with functional groups comprises:

providing a plurality of inorganic nanoparticles;

preparing a surface modifier with functional groups; and

mixing the inorganic nanoparticles and the surface modifier, and then subjected by heating and refluxing to form the surface modified inorganic nanoparticles with functional groups.

4. The method according to claim 1, wherein the functional groups of the surface modifier are selected from the group consisting of photochemically polymerizable organic functional groups, acrylic functional groups, and epoxide groups.

5. The method according to claim 1, wherein the functional groups of the surface modifier are selected from the group consisting of 3-methacryloxypropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane triethoxyvinylsilane, vinyl tris(2-methoxyethoxy)silane, vinyltrimethoxysilane, vinyltriacetoxysilane, and allyltriethoxysilane.

6. The method according to claim 1, wherein the functional groups of the oligomers are acrylate functional groups.

7. The method according to claim 1, wherein the organic matrix comprises a series of acrylic monomers, comprising at least one of monomers with six functional groups, with five functional groups, with four functional groups, with three functional groups, with two functional groups, and with one functional group, or a combination thereof.

8. The method according to claim 1, wherein the organic matrix is selected from thermally polymerizable monomers and photochemically polymerizable monomers, comprising polymerizable organic monomers, acrylic monomers, organic oligomers, monomers with epoxide groups, and silicone.

9. The method according to claim 8, wherein a curing (/hardening) agent is further added into the mixture before curing the mixture to solidify the organic matrix.

10. The method according to claim 8, wherein the surface modified inorganic nanoparticles with functional groups possess the photochemically polymerizable functional groups, and a first light source for performing the photo polymerization has a first wavelength and a first power, and a second light source for curing the mixture has a second wavelength and a second power, wherein the second wavelength is different from the first wavelength, or the second power is larger than the first power while the first and second wavelengths are equal.

11. The method according to claim 1, is applicable in a thin film and sheet fabrication, a device package fabrication, or an optical device fabrication.

12. The method according to claim 1, is applicable in a light emitting diode (LED) package fabrication to form a LED package with gradient refraction index.

13. A structure with gradient composite material, comprising:

a solid organic polymer, polymerized from an organic matrix; and

a plurality of surface modified inorganic nanoparticles with functional groups or oligomers with functional groups, distributed in the solid organic polymer, the surface modified inorganic nanoparticles comprising at least one kind of metal oxide nanoparticles, metal nanoparticles and semiconductor nanoparticles, the surface modified inorganic nanoparticles with functional groups or oligomers with functional groups presenting a gradient distribution in the solid organic polymer;

wherein the surface modified inorganic nanoparticles with functional groups or oligomers with functional groups have higher polymerization rate than the organic matrix under a gradient-generating step.

14. The structure according to claim 13, having at least one of properties of gradient refraction index, gradient hardness, gradient electrical conductivity and gradient thermal conductivity.

15. The structure according to claim 13, wherein the surface modified inorganic nanoparticles comprises plural nanoparticles with the same or different concentrations of the functional groups, and the surface modified inorganic nanoparticles with higher concentration of functional groups have the larger tendency of aggregation.

16. The structure according to claim 13, having a gradient refraction index, and a portion comprising higher concentration of the surface modified inorganic nanoparticles with functional groups has higher refraction index, and other portion comprising lower concentration of the surface modified inorganic nanoparticles with functional groups has lower refraction index.

17. The structure according to claim 13, having the gradient distribution, and a portion comprising higher concentration of the surface modified inorganic nanoparticles with functional groups or higher concentration of oligomers with functional groups has higher hardness.

18. The structure according to claim 13, wherein the surface modified inorganic nanoparticles with functional groups distributed in the solid organic polymer at least comprises a first concentration, a second concentration and a third concentration of the surface modified inorganic nanoparticles with functional groups, and the first concentration of the nanoparticles is larger than the second concentration of the nanoparticles, the second concentration of the nanoparticles is larger than the third concentration of the nanoparticles,

wherein the first concentration of the surface modified inorganic nanoparticles with functional groups have the larger tendency of aggregation than the second concentration of the surface modified inorganic nanoparticles with functional groups, and the second concentration of the surface modified inorganic nanoparticles with functional groups have the larger tendency of aggregation than the third concentration of the surface modified inorganic nanoparticles with functional groups.

19. The structure according to claim 18, wherein plural portions comprising the first, second and third concentrations of the surface modified inorganic nanoparticles with functional groups respectively generate a first refraction index, a second refraction index and a third refraction index, and the first refraction index is larger than the second refraction index, and the second refraction index is larger than the third refraction index.

20. The structure according to claim 18, wherein plural portions comprising the first, second and third concentrations of the surface modified inorganic nanoparticles with functional groups respectively generate a first hardness, a second hardness and a third hardness, and the first hardness is larger than the second hardness, and the second hardness is larger than the third hardness.

21. The structure according to claim 13, wherein the surface modified inorganic nanoparticles with functional groups are metal oxide nanoparticles, selected from the group consisting of titanium dioxide (TiO₂), zirconium oxide (ZrO₂), silicon dioxide (SiO₂), zinc oxide (ZnO), cerium oxide (CeO₂), cadmium oxide (CdO), aluminium oxide (Al₂O₃), ferric oxide (Fe₂O₃), tantalum(V) oxide (Ta₂O₅), copper(I) oxide (Cu₂O), indium oxide (In₂O₃), lanthanum(III) oxide (La₂O₃), vanadium(V) oxide (V₂O₅), molybdenum(VI) oxide (MoO₃) and tungsten(VI) oxide (WO₃).

22. The structure according to claim 13, wherein the modified functional groups are one of photochemically or thermal polymerizable organic functional groups, acrylic functional groups, vinyl groups, and epoxide groups.

23. The structure according to claim 13, wherein the modified functional groups of the nanoparticles are selected from the group consisting of 3-methacryloxypropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane triethoxyvinylsilane, vinyl tris(2-methoxyethoxy)silane, vinyltrimethoxysilane, vinyltriacetoxysilane, and allyltriethoxysilane.

24. The structure according to claim 13, wherein the functional groups of the oligomers are acrylate functional groups.

25. The structure according to claim 13, wherein the solid organic polymer is formed by polymerizing the organic matrix from a series of acrylic monomers, comprising at least one of monomers with six functional groups, with five functional groups, with four functional groups, with three functional groups, with two functional groups, and with one functional group or a combination thereof.

26. The structure according to claim 13, wherein the solid organic polymer is selected from thermally polymerizable monomers and photochemically polymerizable monomers, comprising polymerizable organic monomers, acrylic monomers, organic oligomers, monomers with epoxide groups, and silicone.

27. A package, at least comprising:

a light source; and

a molding compound, encapsulating the light source, and the light source disposed in a bottom portion of the molding compound, the molding compound comprising;

a solid organic polymer, polymerized from an organic matrix; and

a plurality of surface modified inorganic nanoparticles with functional groups or oligomers with functional groups, distributed in the solid organic polymer, and the surface modified inorganic nanoparticles with functional groups or oligomers with functional groups being distributed from the bottom portion to a top portion of the molding compound so that the molding compound presents a gradient refraction index, wherein the surface modified inorganic nanoparticles with functional groups or oligomers with functional groups have higher polymerization rate than the organic matrix under a gradient-generating step.

28. The package according to claim 27, wherein the surface modified inorganic nanoparticles comprises plural nanoparticles with the same or different concentrations of the functional groups, and the surface modified inorganic nanoparticles with higher concentration of functional groups have the larger tendency of aggregation.

29. The package according to claim 27, wherein an aggregating portion having higher concentration of the surface modified inorganic nanoparticles with functional groups is closer to the light source and possesses higher refraction index, while an aggregating portion having lower concentration of the surface modified inorganic nanoparticles with functional groups is further from the light source and possesses lower refraction index.

30. The package according to claim 27, wherein the light source is a light emitting diode, and the surface modified inorganic nanoparticles are plural metal oxide nanoparticles with functional groups, or plural core-shell nanoparticles having metal oxide shell with functional groups or plural core solely.

31. The package according to claim 30, wherein metal oxides of the surface modified inorganic metal oxide nanoparticles or the core-shell nanoparticles with functional groups are selected from the group consisting of titanium dioxide (TiO₂), zirconium oxide (ZrO₂), silicon dioxide (SiO₂), zinc oxide (ZnO), cerium oxide (CeO₂), cadmium oxide (CdO), aluminium oxide (Al₂O₃), ferric oxide (Fe₂O₃), tantalum(V) oxide (Ta₂O₅), copper(I) oxide (Cu₂O), indium oxide (In₂O₃), lanthanum(III) oxide (La₂O₃), vanadium(V) oxide (V₂O₅), molybdenum(VI) oxide (MoO₃) and tungsten(VI) oxide (WO₃), and cores of the core-shell nanoparticles or cores solely are selected from the group consisting of CdSe, Cd_xZn_1-xSe (0.01≦

x≦

0.99), Cd_xZn_1-xS (0.01≦

x≦

0.99), Cd_xZn_1-xS_ySe_1-y (0.01≦

x≦

0.99 and 0.01≦

y≦

0.99), CdSe—

ZnS, CdSe—

CdTe, CdTe, CdS, CdS—

ZnS, CdSe—

CdTe—

ZnSe, ZnS, ZnTe, PbS, PbSe, PbTe, ZnO, and Si.

32. The package according to claim 27, wherein the modified functional groups are selected from the group consisting of photochemically polymerizable organic functional groups, acrylic functional groups, and epoxide groups.

33. The package according to claim 27, wherein the modified functional groups of the nanoparticles are selected from the group consisting of 3-methacryloxypropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane triethoxyvinylsilane, vinyl tris(2-methoxyethoxy)silane, vinyltrimethoxysilane, vinyltriacetoxysilane, and allyltriethoxysilane.

34. The package according to claim 27, wherein the functional groups of the oligomers are acrylate functional groups.

35. The package according to claim 27, wherein the solid organic polymer is selected from thermally polymerizable monomers and photochemically polymerizable monomers, comprising polymerizable organic monomers, acrylic monomers, organic oligomers, monomers with epoxide groups, and silicone.

36. A substrate with composite material, at least comprising:

a first surface and a second surface disposed opposite;

an acrylic polymer or an polyepoxide, polymerized from an acrylic matrix or an epoxy matrix, the acrylic polymer or the polyepoxide comprising;

a concentrating sub-area, relatively close to the first surface; and

a diffusing sub-area, relatively close to the second surface; and

a plurality of surface modified inorganic nanoparticles with functional groups or oligomers with functional groups distributed in the acrylic polymer or the polyepoxide and further presenting a gradient distribution, and the surface modified inorganic nanoparticles comprising at least one kind of metal oxide nanoparticles, metal nanoparticles and semiconductor nanoparticles, more surface modified inorganic nanoparticles or oligomers distributed in the concentrating sub-area than in the diffusing sub-area, wherein the surface modified inorganic nanoparticles with functional groups or oligomers with functional groups have higher polymerization rate than the acrylic matrix under a gradient-generating step.

37. The substrate according to claim 36, wherein the surface modified inorganic nanoparticles comprises plural nanoparticles with the same or different concentrations of the functional groups, and the surface modified inorganic nanoparticles or oligomers with higher concentration of functional groups having the larger tendency of aggregation and being closer to the concentrating sub-area, while the surface modified inorganic nanoparticles or oligomers with lower concentration of functional groups being closer to the diffusing sub-area,

wherein an aggregation tendency of the surface modified inorganic nanoparticles with functional groups or oligomers with functional groups distributed in the acrylic polymer or the polyepoxide presents the gradient distribution, from higher aggregation tendency at the first surface to lower aggregation tendency at the second surface.

38. The substrate according to claim 36, presenting the gradient distribution from the first surface to the second surface, wherein the concentrating sub-area aggregated with higher concentration of the surface modified inorganic nanoparticles or oligomers with functional groups has higher hardness, while the diffusing sub-area distributed with lower concentration of the surface modified inorganic nanoparticles or oligomers with functional groups has lower hardness.

39. The substrate according to claim 36, wherein a first hardness of the first surface is higher than a second hardness of the second surface.

40. The substrate according to claim 36, wherein when the inorganic nanoparticles are plural metal oxide nanoparticles, the inorganic metal oxide nanoparticles are M_XO_Y, M is Si, Ti, Zr or Al, and X is 1, 2, or 3, and Y is 2, 3, 4 or 5.

41. The substrate according to claim 36, wherein when the inorganic nanoparticles are plural metal oxide nanoparticles, the inorganic metal oxide nanoparticles are selected from the group consisting of titanium dioxide (TiO₂), zirconium oxide (ZrO₂), silicon dioxide (SiO₂), zinc oxide (ZnO), cerium oxide (CeO₂), cadmium oxide (CdO), aluminium oxide (Al₂O₃), ferric oxide (Fe₂O₃), tantalum(V) oxide (Ta₂O₅), copper(I) oxide (Cu₂O), indium oxide (In₂O₃), lanthanum(III) oxide (La₂O₃), vanadium(V) oxide (V₂O₅), molybdenum(VI) oxide (MoO₃) and tungsten(VI) oxide (WO₃);

when the inorganic nanoparticles are plural inorganic metal nanoparticles, the inorganic metal nanoparticles are selected from the group consisting of Cu, Ag, Au, Ni, Fe, Co; and

when the inorganic nanoparticles are plural inorganic semiconductor nanoparticles, the inorganic semiconductor nanoparticles comprising either plural core-shell nanoparticles having metal oxide shell or plural core solely, and the cores selected from the group consisting of CdSe, Cd_xZn_1-xSe (0.01 x 0.99), Cd_xZn_1-xS (0.01 x 0.99), Cd_xZn_1-xS_ySe_1-y (0.01 x 0.99 and 0.01 y 0.99), CdSe—

ZnS, CdSe—

CdTe, CdTe, CdS, CdS—

ZnS, CdSe—

CdTe—

ZnSe, ZnS, ZnTe, PbS, PbSe, PbTe, ZnO, and Si.

42. The substrate according to claim 36, wherein the modified functional groups are selected from the group consisting of photochemically polymerizable organic functional groups, acrylic functional groups, and epoxide groups.

43. The substrate according to claim 36, wherein the modified functional groups of the nanoparticles are selected from the group consisting of 3-methacryloxypropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane triethoxyvinylsilane, vinyl tris(2-methoxyethoxy)silane, vinyltrimethoxysilane, vinyltriacetoxysilane, and allyltriethoxysilane.

44. The substrate according to claim 36, wherein the functional groups of the oligomers are acrylate functional groups.

45. The substrate according to claim 36, wherein the acrylic polymer is polymerized from a series of acrylic monomers, comprising at least one of monomers with six functional groups, with five functional groups, with four functional groups, with three functional groups, with two functional groups, and with one functional group, or a combination thereof.