KR101939408B1 - Led의 리플렉터용 열경화성 실리콘 수지 조성물, 및 이를 이용한 led용 리플렉터 및 광반도체 장치 - Google Patents

Led의 리플렉터용 열경화성 실리콘 수지 조성물, 및 이를 이용한 led용 리플렉터 및 광반도체 장치 Download PDF

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KR101939408B1
KR101939408B1 KR1020130040758A KR20130040758A KR101939408B1 KR 101939408 B1 KR101939408 B1 KR 101939408B1 KR 1020130040758 A KR1020130040758 A KR 1020130040758A KR 20130040758 A KR20130040758 A KR 20130040758A KR 101939408 B1 KR101939408 B1 KR 101939408B1
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reflector
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silicone resin
resin composition
mass
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KR20130116813A (ko
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도시오 시오바라
츠토무 가시와기
요시히라 하마모토
요시히로 츠츠미
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신에쓰 가가꾸 고교 가부시끼가이샤
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Abstract

본 발명은 내열, 내광성이 우수하고, 광이 외부로 누설되는 것도 적으며, 특히 매트릭스어레이상의 리플렉터로서 바람직한 경화물을 제공하는 열경화성 실리콘 수지 조성물을 제공하는 것을 목적으로 한다.
본 발명의 LED의 리플렉터용 열경화성 실리콘 수지 조성물은, (A) 하기 평균 조성식 (1)로 표시되고, 1 분자 중에 적어도 2개의 알케닐기를 갖는 오르가노폴리실록산, (B) 하기 일반식 (2)로 표시되는 직쇄상 오르가노히드로젠폴리실록산 및/또는 하기 평균 조성식 (3)으로 표시되는 분지상 오르가노히드로젠폴리실록산, (C) 부가 반응 촉매, (D) 산화티탄, 산화아연, 산화마그네슘, 탄산바륨, 규산마그네슘, 황산아연, 황산바륨으로부터 선택되는 백색 안료, (E) (D) 성분 이외의 무기 충전제를 함유하는 것을 특징으로 한다.
Figure 112013032283310-pat00032

Figure 112013032283310-pat00033

Figure 112013032283310-pat00034

Description

LED의 리플렉터용 열경화성 실리콘 수지 조성물, 및 이를 이용한 LED용 리플렉터 및 광반도체 장치 {HEAT CURABLE SILICONE RESIN COMPOSITION FOR REFLECTOR OF LED, AND REFLECTOR FOR LED AND OPTICAL SEMICONDUCTOR DEVICE USING THE SAME}

본 발명은 LED용 리플렉터를 성형하기 위한 열경화성 실리콘 수지 조성물, 및 이를 이용한 LED용 리플렉터 및 광반도체 장치에 관한 것이다.

LED(발광 다이오드(Light Emitting Diode)) 등의 광반도체 소자는, 가두 디스플레이나 자동차 램프, 주택용 조명 등의 다양한 인디케이터나 광원으로서 이용되고 있다. LED용 리플렉터 재료로서, 폴리프탈아미드 수지(PPA) 등의 열가소성 수지가 대량으로 사용되고 있다. 또한, 최근에는 산 무수물을 경화제로 한 에폭시 수지 등의 열경화성 수지도 리플렉터용 재료로서 사용되고 있다.

LED용 리플렉터 재료로서 실리콘 수지나 에폭시 수지 등의 열경화성 수지를 사용할 수 있다는 것은 이미 특허문헌 1 내지 5, 7 내지 9에 기재되어 있다. 또한, 매트릭스어레이형 리플렉터에 대해서는 특허문헌 6에 기재되어 있다.

그러나, 최근 액정 텔레비젼의 백 라이트나 일반 조명용 광원으로서 LED 소자의 고휘도화가 급속히 진전되고 있고, LED의 신뢰성이나 내구성에 대한 요구도 거세져, 종래부터 리플렉터로서 사용되고 있는 액정 중합체나 PPA(폴리프탈아미드) 등의 열가소성 수지, 또는 에폭시 수지 등의 열경화성 수지로는 열과 광을 동시에 받는 환경에서 열화가 심하고, 수지가 변색되어 광의 반사율이 저하되기 때문에 사용할 수 없다는 문제가 발생하고 있다.

특허문헌 1 내지 3에서는 에폭시 수지나 실리콘 수지가 기재되어 있지만 수지 그 자체에 대해서는 상세하게 기술되어 있지 않다. 일반적으로 실리콘 수지라고 해도 미경화된 상태로 액상 내지 고형인 것, 추가로 경화 후에는 겔상, 고무상 내지 딱딱한 수지상의 것까지 있다.

경화 후에 겔상이 되는 수지로는 리플렉터로서 사용하는 것은 어렵지만, 고무상이 되는 수지로는 리플렉터를 성형하는 것이 가능하다. 그러나, 경화 후에 고무상이 되는 수지를 이용하여 금속 프레임 상에 표면 실장 매트릭스어레이형 리플렉터를 편면 성형하여도, 탄성률이 낮기 때문에 기판 전체의 휘어짐은 거의 발생하지 않지만, 실온에서 탄성률이 낮기 때문에 외력으로 패키지나 리드가 용이하게 변형되어 와이어본드가 단선되거나, 리플렉터와 LED용 밀봉재의 계면에서 박리나 밀봉재가 파단되는 등의 불편이 발생한다는 문제가 있다.

한편, 경화 후에 수지상의 딱딱한 경화물을 제공하는 실리콘 수지로 리플렉터를 제조하면, 탄성률이 높기 때문에 기판 전체가 크게 휘어져 다이싱할 수 없다는 문제가 있다. 이 때문에, 휘어짐을 방지하기 위해, 팽창계수를 금속 프레임에 가까워지도록 무기질 충전재를 다량으로 충전하는 처방이 일반적으로 취해지고 있다. 이 방법으로는 유동성이 저하되고, 매트릭스어레이형의 리플렉터를 트랜스퍼 성형으로 제조하면 미충전이 발생한다는 문제가 있었다.

또한, 일반적으로 경화된 실리콘 수지 그 자체와 무기 충전재의 굴절률이 가깝기 때문에, 리플렉터 재료를 성형하여 얻어지는 리플렉터의 벽 두께가 얇은 경우, 발광 소자로부터 발하는 광이 외부로 누설된다는 문제점이 발생하고 있다.

일본 특허 공개 (평)2006-156704호 공보 일본 특허 공개 제2007-329219호 공보 일본 특허 공개 제2007-329249호 공보 일본 특허 공개 제2008-189827호 공보 일본 특허 공개 제2006-140207호 공보 일본 특허 공개 제2007-235085호 공보 일본 특허 공개 제2007-297601호 공보 일본 특허 공개 제2009-21394호 공보 일본 특허 공개 제2009-155415호 공보

본 발명은 상기 사정을 감안하여 이루어진 것으로, 내열, 내광성이 우수하고, 광의 외부로의 누설도 적으며, 리플렉터, 특히 매트릭스어레이상의 리플렉터로서 바람직한 경화물을 제공하는 열경화성 실리콘 수지 조성물, 상기 조성물로 성형한 LED용 리플렉터, 및 상기 LED용 리플렉터를 사용한 광반도체 장치를 제공하는 것을 목적으로 한다.

상기 과제를 해결하기 위해서, 본 발명에 따르면,

(A) 하기 평균 조성식 (1)로 표시되고, 1 분자 중에 적어도 2개의 알케닐기를 갖는 오르가노폴리실록산 45 내지 90 질량부

Figure 112013032283310-pat00001

(식 중, R1은 서로 독립적으로 알케닐기 및 아릴기를 갖지 않는 치환 또는 비치환된 1가 탄화수소기이고, R2는 아릴기이고, R3은 알케닐기이고, R0은 수소 원자, 메틸기 및 에틸기 중 어느 하나이며, a는 0.4 내지 1.0, b는 0 내지 0.5, c는 0.05 내지 0.5, d는 0 내지 0.5의 수이고, a+b+c+d=1.0 내지 2.0을 만족시키는 수임)

(B) 1 분자 중에 적어도 2개의 규소 원자에 직결된 수소 원자를 갖는, 하기 일반식 (2)로 표시되는 직쇄상 오르가노히드로젠폴리실록산 및/또는 하기 평균 조성식 (3)으로 표시되는 분지상 오르가노히드로젠폴리실록산 10 내지 55 질량부

(단, 상기 (A) 성분 및 상기 (B) 성분의 합계는 100 질량부임)

Figure 112013032283310-pat00002

(식 중, R4는 서로 독립적으로 알케닐기를 갖지 않는 치환 또는 비치환된 1가 탄화수소기이고, R5는 수소이고, n은 1 내지 10의 정수임)

Figure 112013032283310-pat00003

(식 중, R7은 서로 독립적으로 알케닐기 및 아릴기