Curable resin composition for forming seal part, laminate and process for its production

Abstract

To provide a curable resin composition for forming a seal part, which is capable of easily forming a continuous seal part and which is capable of maintaining the shape of the seal part during a period of from immediately after the formation of an uncured seal part until a liquid material is supplied to a region enclosed by the seal part and the seal part is cured, and a laminate which has minimal defects and whereby a resin layer interposed between first and second plates can be made thick. One having a viscosity of from 500 to 3,000 Pa·s at 25° C. is used as the curable resin composition for forming a seal part to form an uncured seal part 12 enclosing the periphery of a liquid material (curable resin composition 14 for forming a resin layer) interposed between a first plate (display device 50 ) and a second plate (transparent plate 10 ).

1 . A curable resin composition for forming a seal part, which is a curable resin composition to form a seal part enclosing the periphery of a layer made of a liquid material interposed between first and second plates and which has a viscosity of from 500 to 3,000 Pa·s at 25° C. 
     
     
         2 . The curable resin composition for forming a seal part according to  claim 1 , wherein the liquid material is a curable resin composition for forming a resin layer. 
     
     
         3 . The curable resin composition for forming a seal part according to  claim 1 , which is used to form a seal part at the time of producing a laminate by curing a curable resin composition for forming a resin layer interposed between first and second plates, in such a state that the periphery thereof is enclosed by the seal part. 
     
     
         4 . The curable resin composition for forming a seal part according to  claim 1 , which comprises at least one oligomer (A) having a curable group and a number average molecular weight of from 30,000 to 100,000, and at least one monomer (B) having a curable group and a molecular weight of from 125 to 600, wherein the proportion of the monomer (B) is from 15 to 50 mass %, based on the total (100 mass %) of the oligomer (A) and the monomer (B). 
     
     
         5 . The curable resin composition for forming a seal part according to  claim 4 , wherein the curable group is at least one type of group selected from the group consisting of an acryloyloxy group and a methacryloyloxy group. 
     
     
         6 . The curable resin composition for forming a seal part according to  claim 4 , wherein the curable group of the oligomer (A) is an acryloyloxy group, and the curable group of the monomer (B) is a methacryloyloxy group. 
     
     
         7 . The curable resin composition for forming a seal part according to  claim 4 , wherein the oligomer (A) is an urethane oligomer (A1). 
     
     
         8 . The curable resin composition for forming a seal part according to  claim 7 , which contains, as the monomer (B), a monomer (B1) not having a group reactive with an isocyanate group, wherein the urethane oligomer (A1) is one obtained by reacting a polyol with a polyisocyanate in the presence of the monomer (B1) to obtain a prepolymer having an isocyanate group, and then, reacting a monomer (B2) having a curable group and a group reactive with an isocyanate group, to the isocyanate group of the prepolymer. 
     
     
         9 . The curable resin composition for forming a seal part according to  claim 4 , which contains, as the monomer (B), a monomer (B3) having a hydroxy group. 
     
     
         10 . The curable resin composition for forming a seal part according to  claim 4 , which is a photo-curable resin composition containing a photopolymerization initiator (C). 
     
     
         11 . The curable resin composition for forming a seal part according to  claim 10 , which contains, as the photopolymerization initiator (C), at least two types of photopolymerization initiators different in the absorption wavelength region. 
     
     
         12 . A laminate comprising first and second plates, a resin layer interposed between the first and second plates, and a seal part enclosing the periphery of the resin layer, wherein the seal part is made of a cured product of a curable resin composition for forming a seal part having a viscosity of from 500 to 3,000 Pa·s at 25° C. 
     
     
         13 . The laminate according to  claim 12 , wherein the seal part has a width of from 0.3 to 3 mm. 
     
     
         14 . The laminate according to  claim 12 , wherein the seal part has a thickness of from 10 μm to 3 mm. 
     
     
         15 . The laminate according to  claim 12 , which is a transparent laminate comprising first and second plates both being transparent plates, a resin layer interposed between the first and second plates, and a seal part enclosing the periphery of the resin layer. 
     
     
         16 . The laminate according to  claim 12 , which is a display unit comprising first and second plates, of which one is a transparent plate and the other is a display device, a resin layer interposed between the first and second plates, and a seal part enclosing the periphery of the resin layer. 
     
     
         17 . The laminate according to  claim 12 , which is a solar cell module comprising first and second plates, at least one of which is a transparent plate, a resin layer interposed between the first and second plates, a thin-film type solar cell device formed on the surface, on the resin layer side, of at least one of the first and second plates, and a seal part enclosing the periphery of the resin layer. 
     
     
         18 . The laminate according to  claim 12 , which is a display unit comprising first and second plates, at least one of which is a transparent plate, a resin layer interposed between the first and second plates, a display device formed on the surface, on the resin layer side, of at least one of the first and second plates, and a seal part enclosing the periphery of the resin layer. 
     
     
         19 . A process for producing a laminate comprising first and second plates, a resin layer interposed between the first and second plates, and a seal part enclosing the periphery of the resin layer, which process comprises:
 (a) applying a curable resin composition for forming a seal part having a viscosity of from 500 to 3,000 Pa·s at 25° C., along the edge of the surface of a first plate, to form an uncured seal part,   (b) supplying a liquid curable resin composition for forming a resin layer to a region enclosed by the uncured seal part,   (c) laminating a second plate on the curable resin composition for forming a resin layer in a reduced-pressure atmosphere of not more than 100 Pa, to obtain a laminate having the curable resin composition for forming a resin layer hermetically sealed by the first and second plates and the uncured seal part, and   (d) curing the uncured seal part and the curable resin composition for forming a resin layer in such a state that the laminate is placed in a pressure atmosphere of at least 50 kPa.   
     
     
         20 . The process for producing a laminate according to  claim 19 , wherein the thickness of the curable resin composition for forming a resin layer in the laminate obtained in the step (c) is from 10 μm to 3 mm.