Light emitting diode devices, method of manufacture, uses thereof

Patent metadata

Field	Value
Publication number	US-9821523-B2
Application number	US-201314063042-A
Country	US
Kind code	B2
Filing date	Oct 25, 2013
Priority date	Oct 25, 2012
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A light emitting diode lighting device contains a light emitting diode and a lighting device component, wherein the device component comprises a polycarbonate composition comprising a bisphenol A polycarbonate; and 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) in an amount effective to provide a composition wherein a molded sample of the composition has a UL94 rating of V-2 or better at a thickness of 0.9 mm; an absorbance of less than 2 a.u. in the region of 370 to 380 nanometers; and an increase in yellowness index (ΔYI) of 12 or less at 2.5 mm thickness after heat aging at 130° C. for 5,000 hours.

First claim

What is claimed is:

1. A light emitting diode device comprising
a light emitting diode, and
a device component, wherein the device component comprises a polycarbonate composition comprising
a bisphenol A polycarbonate; and
2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one) in an amount effective to provide a composition wherein a molded sample of the composition has
a UL94 rating of V-2 or better at a thickness of 0.9 mm;
an absorbance of less than 2 a.u. in the region of 370 to 380 nanometers; and
for a molded sample of the composition having a thickness of 2.5 mm, an increase in yellowness index (ΔYI) of 12 or less after heat aging at 130° C. for 5,000, as measured by ASTM D1925,
wherein the bisphenol A polycarbonate comprises less than or equal to 150 ppm free hydroxyl groups and less than or equal to 2 ppm sulfur as measured by a Total Sulfur Analysis based on combustion and coulometric detection, and a molded sample of the bisphenol A polycarbonate has: a yellowness index of 1.5 or less measured by ASTM D1925, and an increase in yellowness index of less than 3 after 2,000 hours of heat aging at 130° C. as measured by ASTM D 1925.

2. The light emitting diode device of claim 1 , wherein the device is a lighting device.

3. The device of claim 1 , wherein the bisphenol A polycarbonate is an interfacially polymerized polycarbonate.

4. The device of claim 1 , wherein the bisphenol A polycarbonate is an interfacially polymerized polycarbonate manufactured from bisphenol A having a purity of greater than or equal to 99.65 wt. % and a sulfur content of less than or equal to 2 ppm.

5. The device of claim 1 , wherein the bisphenol A polycarbonate is a melt polymerized polycarbonate.

6. The device of claim 1 , wherein the bisphenol A polycarbonate comprises a linear bisphenol A polycarbonate.

7. The device of claim 1 , wherein the bisphenol A polycarbonate comprises a branched bisphenol A polycarbonate having a branching level of greater than or equal to 0.35 wt. %.

8. The device of claim 1 , wherein the bisphenol A polycarbonate comprises a linear bisphenol A polycarbonate and a branched bisphenol A polycarbonate.

9. The device of claim 1 , wherein the polycarbonate composition further comprises an additional polycarbonate derived from a bisphenol, wherein the additional polycarbonate is different from the bisphenol A polycarbonate.

10. The device of claim 9 , wherein the additional polycarbonate is a homopolycarbonate derived from a bisphenol that is not bisphenol A, a copolycarbonate derived from more than one bisphenol, a copolymer derived from a bisphenol and comprising an aliphatic ester unit, or an aromatic ester unit, a siloxane unit or a combination comprising at least one of the foregoing units, or a combination comprising at least one of the foregoing polycarbonates.

11. The device of claim 1 , wherein the polycarbonate composition further comprises a light diffuser.

12. The device of claim 11 , wherein the light diffuser comprises crosslinked poly(methyl methacrylate), poly(tetrafluoroethylene), poly(methylsilsesquioxane), or a combination comprising at least one of the foregoing.

13. The device of claim 1 , wherein the polycarbonate composition further comprises potassium perfluorobutane sulfonate, potassium perfluorooctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate, or a combination comprising at least one of the foregoing.

14. The device of claim 1 , wherein the polycarbonate composition further comprises a conversion material.

15. The device of claim 14 , wherein the conversion material is a strontium silicate yellow conversion material, a yttrium aluminum garnet doped with a rare earth element, a terbium aluminum garnet doped with a rare earth element, a silicate conversion material, a nitride conversion material, a nitrido silicate conversion material, a nitride orthosilicate conversion material, an oxonitridoaluminosilicates conversion material, or a combination comprising at least one of the foregoing conversion materials.

16. The device of claim 14 , wherein the conversion material comprises a silicone oil coating or an amorphous silica coating.

17. The device of claim 1 , wherein the polycarbonate composition comprises less than 10 ppm of an ultraviolet light absorbing agent having a hydroxyl group.

18. The device of claim 1 , wherein the polycarbonate composition contains less than 10 ppm of 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol.

19. The device of claim 1 , wherein the polycarbonate composition does not contain 2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol.

20. The device of claim 1 , wherein the polycarbonate composition contains less than 1000 ppm of an additive having a hydroxyl group.

21. The device of claim 1 , wherein the polycarbonate composition comprises 0.2 to 1 wt. % of the 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one), based on the total weight of the polycarbonate composition.

22. The device of claim 1 , wherein the polycarbonate composition comprises:
90 to 99.9 wt. % of the bisphenol A polycarbonate,
0.001 to 1 wt. % of the 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one),
0.0001 to 1 wt. % of a thermal stabilizing additive,
0.0001 to 1 wt. % of an antioxidant,
0.001 to 1 wt. % of a mold release agent,
a flame retardant comprising a phosphorus-containing flame retardant, a halogen-containing flame retardant, an inorganic flame retardant, or a combination comprising at least one of the foregoing flame retardant, the flame retardant being present in an amount of 0.01 to 10 parts by weight based on 100 parts by weight of the polycarbonate composition,
0 to 1 wt. % of a colorant,
0 to 1% of a gamma-stabilizing agent,
0 to 10% of a filler,
0 to 20 wt. % of a conversion material,
0 to 1.5 wt. % of a light diffuser, or a combination comprising at least one of the foregoing optional materials.

23. The device of claim 22 , comprising 0.001 to 1.5 wt. % of a light diffuser, wherein the light diffuser is a poly(alkyl acrylate), a poly(alkyl methacrylate), a poly(alkylsilsequioxane), a poly(tetrafluoroethylene), or a combination comprising at least one of the foregoing.

24. The device of claim 22 , wherein no light diffuser is present and a molded article of the polycarbonate composition has transmission level greater than or equal to 90% at 2.5 mm thickness as measured by ASTM D1003-00.

25. The device of claim 1 , wherein the polycarbonate composition comprises:
95 to 99.8 wt. % of the bisphenol A homopolycarbonate,
0.001 to 0.5 wt. % of the 2,2′-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one),
0.0001 to 1 wt. % of a thermal stabilizing additive,
0.0001 to 1 wt. % of an antioxidant,
0.001 to 1 wt. % of a mold release agent,
a flame retardant, wherein the flame retardant is potassium perfluorobutane sulfonate, potassium diphenylsulfone sulfonate, or a combination comprising at least one of the foregoing flame retardants, and the flame retardant is present in an amount of 0.01 to 10 parts by weight based on 100 parts by weight of the polycarbonate composition,
0.001 to 1.5 wt. % of a light diffuser, wherein the light diffuser is a poly(alkyl acrylate), a poly(alkyl methacrylate), a poly(alkylsilsequioxane), a poly(tetrafluoroethylene), or a combination comprising at least one of the foregoing light diffusers,
0 to 1 wt. % of a colorant,
0 to 1% of a gamma-stabilizing agent,
0 to 1

Assignees

• Sabic Innovative Plastics Ip Bv
• Sabic Global Technologies Bv

Inventors

• Van Heerbeek Hendrikus Petrus Cornelis
• Huijs Frank
• De Brouwer Johannes
• Hein Christopher Luke

Classifications

• H01L33/56

  Electricity · mapped topic

• B29D11/0074 Primary

  Production of other optical elements not provided for in B29D11/00009- B29D11/0073 · CPC title

• C08K5/357

  Six-membered rings · CPC title

• H01L33/501

  Electricity · mapped topic

• C08L69/00

  Compositions of polycarbonates; Compositions of derivatives of polycarbonates · CPC title