Optoelectronic devices and coatings therefore

• US 8,525,191 B2
• Filed: 03/30/2012
• Issued: 09/03/2013
• Est. Priority Date: 04/01/2011
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Zhou, Jian, Pickett, James Edward, Chakravarti, Shreyas
• Primary Examiner(s): Soward, Ida M
• Application Number:
  US13/435,161
• Publication Number:
  US 20120248497A1
• Time in Patent Office: 522 Days
• Field of Search: 257/80, 257/85, 257/E31.096, 257/E31.099, 257/E31.105, 257/E33.076, 257/E33.077, 257/E51.036
• US Class Current: 257/80
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2933/0091 Scattering means in or on the semiconductor body or semiconductor body package H01L33/22 takes precedence
• CPC Class Codes: H01L 31/0481 characterised by the composition of the encapsulation material
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: H01L 33/56 Materials, e.g. epoxy or silicone resin
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

An optoelectronic device assembly can include: a coated element and an optoelectronic device on the coated element. The coated element can include a thermoplastic substrate and a protective weathering layer. The thermoplastic substrate can include a bisphenol-A polycarbonate homopolymer and a polycarbonate copolymer, and wherein the polycarbonate copolymer is selected from a copolymer of tetrabromobisphenol A carbonate and BPA carbonate; a copolymer of 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine carbonate and BPA carbonate; a copolymer of 4,4′-(1-phenylethylidene) biphenol carbonate and BPA carbonate; a copolymer of 4,4′-(1-methylethylidene) bis[2,6-dimethyl-phenol]carbonate and BPA carbonate; and combinations comprising at least one of the foregoing. The protective weathering layer can include resorcinol polyarylate and polycarbonate.

Claims

1. An optoelectronic device assembly comprising:

a coated element, comprising

thermoplastic substrate comprising a bisphenol-A polycarbonate homopolymer and a polycarbonate copolymer, and wherein the polycarbonate copolymer is selected from a copolymer of tetrabromobisphenol A carbonate and BPA carbonate;

a copolymer of 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine carbonate and BPA carbonate;

a copolymer of 4,4′

-(1-phenylethylidene)biphenol carbonate and BPA carbonate;

a copolymer of 4,4′

-(1-methylethylidene)bis[2,6-dimethyl-phenol]carbonate and BPA carbonate; and

combinations comprising at least one of the foregoing; and

a protective weathering layer comprising resorcinol polyarylate and polycarbonate; and

an optoelectronic device on the coated element, wherein the optoelectronic device is selected from a light emitting diode and a photovoltaic cell.

2. The assembly of claim 1, wherein the protective weathering layer comprises greater than or equal to 2.5 wt % of a UV absorbers, based upon a total weight of the protective weathering layer, wherein the UV absorber is selected from 4,6-dibenzoylresorcinol, silylated 4,6-dibenzoylresorcinols, 2,4-diphenyl-6-(2′

-hydroxy-4′

alkoxyphenyl)-1,3,5-triazines, and combinations comprising at least one of the foregoing.

3. The assembly of claim 1, wherein the protective weathering layer comprises triazine of the formula:

4. The assembly of claim 3, wherein R₁, R₂, and R₃=H.

5. The assembly of claim 4, wherein R₄=C₆H₁₃.

6. The assembly of claim 4, wherein R₄=CH₂CH₂OOCC₇H₁₅.

7. The assembly of claim 1, wherein the protective weathering layer comprises a block copolymer comprising the resorcinol polyarylate and the polycarbonate, and wherein the block copolymer has a resorcinol polyarylate block content of less than or equal to 40 wt %.

8. The assembly of claim 1, wherein the protective weathering layer further comprises a matrix selected from silicone, poly(meth)acrylates, polycarbonates, and combinations comprising at least one of the foregoing.

9. The assembly of claim 1, wherein the protective weathering layer has an engineered surface texture selected from a plurality of lenses, microlenses, linear prisms, prisms, pyramids, lenticular structures, and combinations comprising at least one of the foregoing.

10. The assembly of claim 9, wherein the engineered surface texture is on a side of the protective weathering layer opposite the thermoplastic substrate.

11. The assembly of claim 1, wherein the thermoplastic substrate has a thermal shrinkage ratio less than 1% along both the extrusion direction and the cross-web direction after a 30-minute treatment at 150°

C.

12. The assembly of claim 1, wherein the thermoplastic substrate and protective weathering layer are co-extruded.

13. The assembly of claim 1, further comprising a barrier coating layer comprising at least one zone substantially organic in composition and at least one zone substantially inorganic in composition.

14. The assembly of claim 1, further comprising a planarizing layer selected from an epoxy based resin, an acrylic based resin, a silicone resin, and a combination comprising at least one of the foregoing.

15. The assembly of claim 14, wherein the planarizing layer has a thickness of 1 nm to 100 μ

m.

16. The assembly of claim 1, further comprising a UV-cured acrylic-colloidal silica coating layer.

17. The assembly of claim 1, wherein the protective weathering layer comprises dibenzoylresorcinol of the formula:

18. The assembly of claim 17, wherein R₅, R₆, and R₇=H.

19. The assembly of claim 1, wherein the protective weathering layer comprises dibenzoylresorcinol of the formula:

20. The assembly of claim 19, wherein the thermoplastic polycarbonate comprises a bisphenol-A polycarbonate homopolymer and a polycarbonate copolymer, and wherein the polycarbonate copolymer is selected from a copolymer of tetrabromobisphenol A carbonate and BPA carbonate;

a copolymer of 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine carbonate and BPA carbonate;

a copolymer of 4,4′

-(1-phenylethylidene)biphenol carbonate and BPA carbonate;

a copolymer of 4,4′

-(1-methylethylidene)bis[2,6-dimethyl-phenol]carbonate and BPA carbonate; and

combinations comprising at least one of the foregoing.

21. The assembly of claim 1, further comprising a primer located between the weathering layer and the thermoplastic substrate.

22. The assembly of claim 1, further comprising an adhesive layer located between the optoelectronic device and the thermoplastic substrate.

23. An optoelectronic device assembly comprising:

a coated element, comprising

thermoplastic substrate comprising a material selected from aromatic polycarbonate and polyester, and combinations comprising at least one of the foregoing materials; and

a protective weathering layer comprises a UV absorber and a block copolymer comprising the resorcinol polyarylate and the polycarbonate, wherein the block copolymer has a resorcinol polyarylate block content of less than or equal to 40 wt %;

an optoelectronic device on the coated element, wherein the optoelectronic device is selected from a light emitting diode and a photovoltaic cell.

24. The assembly of claim 23, wherein the thermoplastic substrate comprises a bisphenol-A polycarbonate homopolymer and a polycarbonate copolymer, and wherein the polycarbonate copolymer is selected from a copolymer of tetrabromobisphenol A carbonate and BPA carbonate;

a copolymer of 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine carbonate and BPA carbonate;

a copolymer of 4,4′

-(1-phenylethylidene)biphenol carbonate and BPA carbonate;

a copolymer of 4,4′

-(1-methylethylidene)bis[2,6-dimethyl-phenol]carbonate and BPA carbonate; and

combinations comprising at least one of the foregoing.

25. The assembly of claim 23, wherein the protective weathering layer has a UV absorbance loss rate at 330 nm of less than or equal to 0.15 A/year as estimated from filtered xenon arc exposure and/or having a rate of erosion of less than or equal to 5 μ

m per year as estimated from filtered xenon arc exposure.