JP6285346B2 - 透明樹脂組成物、該組成物からなる接着剤、該組成物からなるダイボンド材、該組成物を用いた導電接続方法、及び該方法によって得られた光半導体装置 - Google Patents
透明樹脂組成物、該組成物からなる接着剤、該組成物からなるダイボンド材、該組成物を用いた導電接続方法、及び該方法によって得られた光半導体装置 Download PDFInfo
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- JP6285346B2 JP6285346B2 JP2014247534A JP2014247534A JP6285346B2 JP 6285346 B2 JP6285346 B2 JP 6285346B2 JP 2014247534 A JP2014247534 A JP 2014247534A JP 2014247534 A JP2014247534 A JP 2014247534A JP 6285346 B2 JP6285346 B2 JP 6285346B2
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Images
Classifications
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
- C08F290/06—Polymers provided for in subclass C08G
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/02—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated end groups
- C08F290/06—Polymers provided for in subclass C08G
- C08F290/068—Polysiloxanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/08—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated side groups
- C08F290/14—Polymers provided for in subclass C08G
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F290/00—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups
- C08F290/08—Macromolecular compounds obtained by polymerising monomers on to polymers modified by introduction of aliphatic unsaturated end or side groups on to polymers modified by introduction of unsaturated side groups
- C08F290/14—Polymers provided for in subclass C08G
- C08F290/148—Polysiloxanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/08—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds
- C08L51/085—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds on to polysiloxanes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J183/00—Adhesives based on 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; Adhesives based on derivatives of such polymers
- C09J183/04—Polysiloxanes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J9/00—Adhesives characterised by their physical nature or the effects produced, e.g. glue sticks
- C09J9/02—Electrically-conducting adhesives
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- H—ELECTRICITY
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Description
(A)(A−1) 下記一般式(1)で表される構造を分子中に少なくとも1つ有するオルガノポリシロキサン:100質量部、
(A−2)有機過酸化物:前記(A−1)成分の合計量100質量部に対して、0.1〜10質量部を含むシリコーン組成物と、
(B)平均粒径が1μm以下の導電性粒子と
を含有するものであり、
前記(B)成分の含有量が、前記(A)成分の固形分を基準として0体積%より大きく、かつ0.1体積%未満の範囲であり、
前記透明樹脂組成物を硬化して得られる2mm厚の硬化物の全光線透過率が70%以上であり、かつヘイズ値が60%以下であることを特徴とする透明樹脂組成物を提供する。
(A)(A−1) 下記一般式(1)で表される構造を分子中に少なくとも1つ有するオルガノポリシロキサン:100質量部、
(A−2)有機過酸化物:前記(A−1)成分の合計量100質量部に対して、0.1〜10質量部を含むシリコーン組成物と、
(B)平均粒径が1μm以下の導電性粒子と
を含有するものであり、
前記(B)成分の含有量が、前記(A)成分の固形分を基準として0体積%より大きく、かつ0.1体積%未満の範囲であり、
前記透明樹脂組成物を硬化して得られる2mm厚の硬化物の全光線透過率が70%以上であり、かつヘイズ値が60%以下である透明樹脂組成物である。
(A)シリコーン組成物は、上記の(A−1)成分を100質量部、上記の(A−2)を(A−1)成分の合計量100質量部に対して、0.1〜10質量部を含むものである。
(A−1)成分のオルガノポリシロキサンは、下記一般式(1)で表される構造を分子中に少なくとも1つ有するオルガノポリシロキサンである。
好ましくは下式に示す化合物、
より具体的には、1,3−ビス(3−メタクリロキシプロピル)テトラメチルジシロキサンと1,1,3,3−テトラメチルジシロキサンを酸触媒存在下で平衡化反応する事によって得られる(3−メタクリロキシプロピル)−1,1,3,3−テトラメチルジシロキサンと、脂肪族不飽和基(例えば、エチレン性不飽和基、及びアセチレン性不飽和基が挙げられる。)を含むオルガノポリシロキサンとを、塩化白金酸触媒存在下でヒドロシリル化反応させるとよく、この方法で本発明に好適なものを製造することができるが、前記の合成方法に制限されるものではない。また、脂肪族不飽和基を含むオルガノポリシロキサンは、脂肪族不飽和基を有するオルガノアルコキシシランを含むアルコキシシランの(共)加水分解縮合など公知の方法で製造することができ、市販のものを用いても良い。
(A−2)成分の有機過酸化物は、本発明の透明樹脂組成物を所望の形状に成形した後に、加熱処理を加えて架橋反応により硬化させるために配合される成分であり、目的とする接続温度、接続時間、ポットライフ等により適宜選択する。
本発明の透明樹脂組成物を構成する(B)成分は、平均粒径1μm以下の導電性粒子である。上記導電性粒子は、一次粒径で100nm以下の導電性ナノ粒子であることが好ましい。平均粒径が1μmを超えると、粗大粒子の影響で、後に述べるBLTが5μm以下とはならず、安定した導電性を得ることが難しい。平均粒径の下限に特に制限はない。このような導電性粒子としては、金属ナノ粒子等の金属粒子、導電性無機酸化物等を用いることができ、単独又は2種以上を混合して使用することができる。粒子の好ましい形状として、球状、フレーク状、針状、無定型等が挙げられるが、この限りではない。
組成物の透明性を更に維持し、硬化物の着色、酸化劣化等の発生を抑えるために、2,6−ジ−t−ブチル−4−メチルフェノール等の従来公知の酸化防止剤を本発明の透明樹脂組成物に配合することができる。また、光劣化に対する抵抗性を付与するために、ヒンダードアミン系安定剤等の光安定剤を本発明の透明樹脂組成物に配合することもできる。
パッケージ基板上の第1のリード2に、ダイボンド材1を定量転写し、その上に光半導体素子4を搭載する。次にダイボンド材1を加熱硬化させ、光半導体素子4の下部電極と第1のリード2を電気的に接続する。この際、本発明の導電接続方法では、BLTを5μm以下とする。BLTを5μm以下とする方法としては、例えば、組成物の粘度を調整する方法、組成物の基板への塗布量を調節する方法、光半導体素子を基板にダイボンドする際の圧力を制御する方法等を挙げることができる。次いで、光半導体素子4が搭載されたパッケージ基板を、光半導体素子4の上部電極と第2のリード3に対してワイヤー5を用いて電気的に接続し、光半導体素子4が搭載されたパッケージ基板を得る。次いで、封止材6を定量塗布し、封止材6の加熱硬化を行う。
下記成分を撹拌、混合し、表1に示す組成のシリコーン組成物を調製した。
[(A−1)成分]
(a)下記式に示す、MA単位、M単位、Q単位が、MA:M:Q=1:4:6の割合で含まれ、分子量がポリスチレン換算の重量平均分子量で、5000であるオルガノポリシロキサン。
(A−2)1,1−Di(t−butylperoxy)cyclohexane(商品名:パーヘキサC、日本油脂株式会社製)
下記成分を撹拌、混合してシリコーン組成物(V)を調製した。
((e)成分)平均組成式:MViD300MViのシリコーンオイル:35質量部
((f)成分)M単位とMVi単位とQ単位とから構成され、MVi単位に対するM単位のモル比が6.25であり、Q単位に対するM単位とMVi単位との合計のモル比が0.8であるシリコーンレジン:65質量部
なお、上記の(e)成分、(f)成分において、各成分の平均組成を示す記号は以下の通りの単位を示す。
M:(CH3)3SiO1/2
MVi:(CH2=CH)(CH3)2SiO1/2
D:(CH3)2SiO2/2
Q:SiO4/2
(A−2)1,1−Di(t−butylperoxy)cyclohexane(商品名:パーヘキサC、日本油脂株式会社製):2質量部
(実施例1)
(A)成分として調製例1で得られたシリコーン組成物(I)100質量部、(B)成分の導電性粒子として平均粒径(一次粒子の平均粒子径)0.02μmのSbド―プSnO2粉(ATO、製品名SN−100P、石原産業社製)0.1質量部(シリコーン組成物(I)の固形分を基準として0.015体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分として調製例2で得られたシリコーン組成物(II)100質量部、(B)成分の導電性粒子として平均粒径0.02μmのSbド―プSnO2粉(ATO、製品名SN−100P、石原産業社製)0.1質量部(シリコーン組成物(II)の固形分を基準として0.015体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分として調製例3で得られたシリコーン組成物(III)100質量部、(B)成分の導電性粒子として平均粒径0.02μmのSbド―プSnO2粉(ATO、製品名SN−100P、石原産業社製)0.1質量部(シリコーン組成物(III)の固形分を基準として0.015体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡し、希釈剤としてキシレンを10質量部加え良く混合してペースト状の組成物を調製した。
(A)成分として調製例1で得られたシリコーン組成物(I)100質量部、(B)成分の導電性粒子として平均粒径0.35μmのSbド―プSnO2被覆シリカ粉(製品名ES−650E、比重4.1、チタン工業社製)0.1質量部(シリコーン組成物(I)の固形分を基準として0.024体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分として調製例1で得られたシリコーン組成物(I)100質量部、(B)成分の導電性粒子として平均粒径0.02μmのSbド―プSnO2粉(ATO、製品名SN−100P、石原産業社製)0.01質量部(シリコーン組成物(I)の固形分を基準として0.0015体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分として調製例4で得られたシリコーン組成物(IV)100質量部、(B)成分の導電性粒子として平均粒径0.05μmの銀粉(製品名シルベストC−34、比重10.5、徳力科学研究所社製)0.01質量部(シリコーン組成物(IV)の固形分を基準として0.001体積%)、溶剤としてキシレン5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(比較例1)
(A)成分として調製例1で得られたシリコーン組成物(I)100質量部、(B)成分の導電性粒子として平均粒径0.02μmのSbド―プSnO2粉(ATO、製品名SN−100P、石原産業社製)1.0質量部(シリコーン組成物(I)の固形分を基準として0.15体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分として調製例1で得られたシリコーン組成物(I)100質量部、(B)成分の導電性粒子として平均粒径6.9μmの銀粉(製品名シルベストTCG−7、比重10.5、徳力科学研究所社製)0.1質量部(シリコーン組成物(I)の固形分を基準として0.001体積%)、添加材として、煙霧状シリカ(製品名レオシロールDM−30S、トクヤマ社製)5質量部を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分として比較調製例1で得られたシリコーン組成物(V)100質量部、(B)成分の導電性粒子として平均粒径0.02μmのSbド―プSnO2粉(ATO、製品名SN−100P、石原産業社製)0.1質量部(シリコーン組成物(V)の固形分を基準として0.015体積%)を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
(A)成分としてエポキシ組成物(VI)(エポキシダイボンド材、製品名DX−20C、ヘンケル社製)100質量部、(B)成分の導電性粒子として平均粒径6.9μmの銀粉(製品名シルベストTCG−7、比重10.5、徳力科学研究所社製)310質量部(エポキシ組成物(VI)の固形分を基準として29.5体積%)を混合し、さらに三本ロールで混練処理を行い、減圧脱泡してペースト状の組成物を調製した。
日本電色工業社製 ヘイズメーターNDH−5000SPを用いてヘイズ測定、及び全光線透過率の測定を行った。上記の条件で混合した試料を、2mm厚のセルに流し込み、所定の条件(実施例1〜6、比較例1〜3は150℃、1時間、比較例4は170℃、1時間)で加熱硬化を行い、表面が清浄な2mm厚の硬化物を得、これを測定部にセットし測定した。3度の測定におけるヘイズ値、全光線透過率の平均値を求めた。
実施例及び比較例に示す組成物からなる各ダイボンド材の粘度をE型粘度計(東機産業株式会社製 RE80U)を用いて25℃、50rpmで測定した。
LED用パッケージ基板として、光半導体素子を載置する凹部を有し、その底部に銀メッキされた第1のリードと第2のリードが設けられたLED用パッケージ基板[SMD5050(I−CHIUN PRECISION INDUSTRY CO.,社製、樹脂部PPA(ポリフタルアミド))]、光半導体素子として、主発光ピークが450nmの垂直型LED(SemiLEDs社製 EV−B35A)を、それぞれ用意した。
上記の方法で得られた封止材が充填された光半導体パッケージ全数(120個)の点灯検査を行い(印加電流IF=20mA)、点灯した光半導体装置の数を数えた。
上記の方法で得られた封止材が充填された光半導体パッケージを、市販の室温硬化型エポキシ樹脂で埋包し、光半導体素子の直下が観察できるように切断、研磨し、BLTが観察可能な試料を作製した。得られた試料をレーザー顕微鏡(株式会社キーエンス製 VK−8700)で観察し、光半導体素子−基板間の距離を3点測定し、平均値を求めた。
上記の方法で得られた封止材が充填された光半導体パッケージ10個を、全光束測定システム HM−9100(大塚電子(株)製)を用い、全光束値(Lm)を測定し(印加電流IF=350mA)、平均値を求めた。
上記の方法で得られた封止材が充填された光半導体パッケージのうち10個を、高温下(85℃)で、350mA通電、1000時間点灯した後、試験後のサンプルの通電試験を行い、点灯した光半導体装置の数を数えた。
Claims (9)
- 透明樹脂組成物であって、
(A)(A−1) 下記一般式(1)で表される構造を分子中に少なくとも1つ有するオルガノポリシロキサン:100質量部、
(A−2)有機過酸化物:前記(A−1)成分の合計量100質量部に対して、0.1〜10質量部を含むシリコーン組成物と、
(B)平均粒径が1μm以下の導電性粒子と
を含有するものであり、
前記(B)成分の含有量が、前記(A)成分の固形分を基準として0体積%より大きく、かつ0.1体積%未満の範囲であり、
前記透明樹脂組成物を硬化して得られる2mm厚の硬化物の全光線透過率が70%以上であり、かつヘイズ値が60%以下であることを特徴とする透明樹脂組成物。 - 前記(A−1)成分のオルガノポリシロキサンのZ1が−R4−であり、前記Z2が酸素原子であることを特徴とする請求項1に記載の透明樹脂組成物。
- 前記(A−1)成分のオルガノポリシロキサンのZ1が−R4−O−又は、−R4(CH3)2Si−O−であり、前記Z2が置換又は非置換で同一又は異なってもよい炭素数1〜10の2価の有機基であることを特徴とする請求項1に記載の透明樹脂組成物。
- 前記(A−1)成分のオルガノポリシロキサン中に、0.1mol%以上の(SiO2)単位を有することを特徴とする請求項1から請求項3のいずれか1項に記載の透明樹脂組成物。
- 請求項1から請求項4のいずれか1項に記載の透明樹脂組成物からなるものであることを特徴とする接着剤。
- 請求項1から請求項4のいずれか1項に記載の透明樹脂組成物からなるものであることを特徴とするダイボンド材。
- 前記ダイボンド材を硬化して得られる硬化物はBLT(Bond line thickness)が5μm以下の場合において使用されるものであることを特徴とする請求項6に記載のダイボンド材。
- 請求項1から請求項4のいずれか1項に記載の透明樹脂組成物を用いて、BLTを5μm以下として光半導体素子と基板とを導電接続することを特徴とする導電接続方法。
- 請求項8に記載の導電接続方法によって光半導体素子と基板とが導電接続されたものであることを特徴とする光半導体装置。
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