Method for producing an optical, radiation-emitting component and optical, radiation-emitting component

• US 8,247,263 B2
• Filed: 02/28/2006
• Issued: 08/21/2012
• Est. Priority Date: 02/28/2005
• Status: Expired due to Fees

• Current Assignee: Osram Opto Semiconductors GmbH (Ams-Osram AG)
• Original Assignee: Osram Opto Semiconductors GmbH (Ams-Osram AG)
• Inventors: Braune, Bert, Brunner, Herbert, Jäger, Harald, Sorg, Jörg
• Primary Examiner(s): Landau, Matthew
• Assistant Examiner(s): SNOW, COLLEEN ERIN
• Application Number:
  US11/885,374
• Publication Number:
  US 20080197376A1
• Time in Patent Office: 2,366 Days
• Field of Search: 257/99, 257/E33.005, 257/E33.059, 257/E33.071, 438/40, 264/1.1, 264/1.7, 264/2.7
• US Class Current: 438/99
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 45/02 Transfer moulding, i.e. transferring the required volume of moulding material by a plunger from a "shot" cavity into a mould cavity
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29L 2011/00 Optical elements, e.g. lenses, prisms
• CPC Class Codes: C08G 59/3245 containing only nitrogen as a heteroatom
• CPC Class Codes: C08G 59/4215 cycloaliphatic
• CPC Class Codes: C08G 77/06 Preparatory processes C08G77/045 takes precedence
• CPC Class Codes: C08G 77/42 Block-or graft-polymers containing polysiloxane sequences polymerising aliphatic unsaturated monomers on to a polysiloxane C08F283/12
• CPC Class Codes: C08G 77/455 containing polyamide, polyesteramide or polyimide sequences
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C08L 83/00 Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 83/04 Polysiloxanes
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/48465 the other connecting portion not on the bonding area being a wedge bond, i.e. ball-to-wedge, regular stitch
• 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 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/12044 OLED
• CPC Class Codes: H01L 33/54 : having a particular shape
• CPC Class Codes: H01L 33/56 : Materials, e.g. epoxy or silicone resin

Abstract

The invention relates to a method for producing an optical and a radiation-emitting component by a molding process, and to an optical and a radiation-emitting component having well-defined viscosity.

Claims

1. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups and

exhibiting as second component compounds whose functional groups are selected from imide groups and acrylate groups.

2. The method of claim 1, wherein the component is molded from the hybrid material.

3. The method of claim 1, wherein a hybrid material is employed that exhibits, as first and second components, monomers that are processed to a copolymer.

4. The method of claim 1, wherein a hybrid material is employed that exhibits polymers as first and second components and is processed to a polymer mixture.

5. The method of claim 1, wherein the second component additionally exhibits siloxane groups.

6. The method of claim 1, wherein the hybrid material exhibits a siloxane content of between 10 and 90% by weight.

7. The method of claim 6, wherein the hybrid material exhibits a siloxane content of between 40 and 60% by weight.

8. The method of claim 1, wherein the hybrid material exhibits a viscosity in the range of from 0.5 to 200 Pa s at room temperature.

9. The method of claim 1, wherein the hybrid material is precured to a preproduct, the preproduct being solid at room temperature.

10. The method of claim 9, wherein the preproduct is subjected to size reduction.

11. The method of claim 9, wherein the optical component is formed as a molding from the hybrid material or the preproduct.

12. The method of claim 11, wherein the molding is formed by a method selected from molding, transfer molding and injection molding.

13. The method of claim 12, wherein the preproduct is processed in a transfer molding process.

14. The method of claim 11, wherein the molding is formed in a cavity of a mold.

15. The method of claim 14, wherein a foil is applied to at least part of the surface of the cavity before the molding process.

16. The method of claim 9, wherein the preproduct exhibits a viscosity in the range of from 1 mPa to 30 Pa s at 150°

C.

17. The method of claim 9, wherein the hybrid material or the preproduct is processed by curing to a cured hybrid material.

18. The method of claim 17, wherein the cured hybrid material exhibits a hardness of more than 60 Shore D.

19. The method of claim 17, wherein an optoelectronic component on a substrate is at least partly enclosed during the curing of the hybrid material or the preproduct.

20. The method of claim 19, wherein the optoelectronic component on a substrate is disposed in the mold cavity.

21. The method of claim 9, wherein an internal mold-release agent is added to the hybrid material or the preproduct.

22. The method of claim 9, wherein a material is added to the hybrid material or the preproduct in order to raise the refractive index, the material being chemically bonded to the hybrid material as oxide, as particles or as a combination thereof.

23. The method of claim 22, wherein the material for raising the refractive index exhibits titanium, zirconium and/or sulfur chemically bonded to the hybrid material or to the preproduct.

24. The method of claim 22, wherein to the material for raising the refractive index there is added an oxide that is selected from a group, the group comprising TiO₂, ZrO₂ and α

-Al₂O₃, and/or a non-oxide that comprises gallium nitride.

25. The method of claim 1, wherein the hybrid material exhibits curing times of less than 5 minutes.

26. The method of claim 1 for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the method comprising the following procedural steps:

A) Converting a preproduct, obtained from the hybrid material by precuring, to a liquid or pasty state,

B) Placing the preproduct from procedural step A) in a cavity of a mold, the cavity exhibiting a definite shape, and

C) Curing the preproduct to a solid hybrid material, the optical component being made with a shape largely corresponding to the shape of the cavity.

27. The method of claim 26 with the additional procedural steps to be performed before procedural step A):

A1) Precuring the hybrid material to a preproduct that is solid at room temperature,

A2) Subjecting the solid preproduct to size reduction to a powder or granulate state, and

A3) Converting the preproduct after size reduction to a compact shape.

28. The method of claim 1, wherein a wavelength conversion substance is added to the hybrid material or the preproduct, the wavelength conversion substance exhibiting YAG:

Ca, TAG;

Ce, TbYAG;

Ce, GdYAG;

Ce, GdTbYAG;

Ce, nitrides or silicates or a mixture formed therefrom.

29. The method of claim 1, wherein at least one optoelectronic component on a substrate is encapsulated by the optical component.

30. The method of claim 29, wherein a radiation-emitting semiconductor chip is employed as optoelectronic component.

31. The method of claim 30, wherein a radiation-emitting semiconductor chip capable, when in operation, of emitting radiation is employed, the radiation exhibiting a wavelength in the ultraviolet to green range of wavelengths.

32. The method of claim 29, wherein a substrate is employed that exhibits a leadframe, a printed circuit board, a flex-material-based configuration or a ceramic-based configuration.

33. The method of claim 29, wherein at least portions of the substrate and/or of the optoelectronic component are coated before the molding process with a material that is suitable for enhancing the adhesion to the hybrid material or to the preproduct.

34. The method of claim 1, wherein a multiplicity of optical components are produced and the multiplicity of optical components are subsequently separated.

35. The method of claim 34, wherein separation is effected by cutting, sawing, notching, breaking and/or grinding.

36. An optical component that can be produced by a method of claim 34.

37. The optical component of claim 36, the optical component being a radiation-diffracting optical component, a radiation-refracting optical component, a reflector, a wavelength converter, a package, a portion of a package, an encapsulation, a portion of an encapsulation or a combination thereof.

38. The optical component of claim 37, the radiation-refracting optical component being a spherical lens, an aspherical lens, a cylindrical lens or a Fresnel lens.

39. A disposition comprising an optical component obtainable by a method of claim 1 and an optoelectronic component.

40. The disposition of claim 39, the optical component at least partly enclosing the optoelectronic component.

41. The disposition of claim 39, the disposition being surface-mountable.

42. The method of claim 1 wherein said optical component is formed in a cavity of a molding tool and said optical component is separated from said cavity by a foil.

43. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups; and

wherein the second component additionally exhibits siloxane groups.

44. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein the hybrid material is precured to a preproduct, the preproduct being solid at room temperature; and

wherein the preproduct is subjected to size reduction.

45. The method of claim 44, wherein the preproduct after size reduction is shaped.

46. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein the optical component is produced from a material that comprises a hybrid material, the method comprising the following procedural steps;

A) converting a preproduct, obtained from the hybrid material by precuring, to a liquid or pasty state,

B) placing the preproduct from procedural step A) in a cavity of a mold, the cavity exhibiting a definite shape, and

C) curing the preproduct to a solid hybrid material, the optical component being made with a shape largely corresponding to the shape of the cavity;

with the additional procedural steps to be performed before procedural step A);

A1) precuring the hybrid material to a preproduct that is solid at room temperature,

A2) subjecting the solid preproduct to size reduction to a powder or granulate state, and

A3) converting the preproduct after size reduction to a compact shape.

47. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein the optical component is formed as a molding from the hybrid material or a preproduct, which is produced by precuring the hybrid material, the preproduct being solid at room temperature;

wherein the molding is formed in a cavity of a mold; and

wherein a foil is applied to at least part of the surface of the cavity before the molding process.

48. The method of claim 47, wherein the foil prevents wetting of the surface of the cavity by the hybrid material or the preproduct.

49. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein a material is added to the hybrid material or a preproduct, which is produced by precuring the hybrid material the preproduct being solid at room temperature, in order to raise the refractive index, the material being chemically bonded to the hybrid material as oxide, as particles or as a combination thereof; and

wherein the material for raising the refractive index exhibits titanium, zirconium and/or sulfur chemically bonded to the hybrid material or to the preproduct.

50. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein a material is added to the hybrid material or the preproduct in order to raise the refractive index, the material being chemically bonded to the hybrid material as oxide, as particles or as a combination thereof; and

wherein to the material for raising the refractive index there is added an oxide that is selected from a group, the group comprising TiO₂, ZrO₂ and α

-Al₂O₃, and/or a non-oxide that comprises gallium nitride.

51. The method of claim 50, wherein glass particles are admixed with the material for raising the refractive index.

52. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein at least one optoelectronic component on a substrate is encapsulated by the optical component; and

wherein at least portions of the substrate and/or of the optoelectronic component are coated before the molding process with a material that is suitable for enhancing the adhesion to the hybrid material or to the preproduct.

53. The method of claim 52, wherein the material is a silicate.

54. The method of claim 53, wherein coating is effected by flame silicatization.

55. A method for producing an optical component, wherein the optical component is produced from a material that comprises a hybrid material, the hybrid material

exhibiting as first component at least one compound containing siloxane groups;

exhibiting as second component compounds whose functional groups are selected from epoxide groups, imide groups and acrylate groups;

wherein said optical component is formed in a cavity of a molding tool and said optical component is separated from said cavity by a foil.